Systems and conveyance structures for high power long distance laser transmission

ABSTRACT

There is provided a mobile high power laser system and conveyance structure for delivering high power laser energy to and for performing high power laser operations in remote and difficult to access locations. There is further provide such systems with high power laser, handling equipment and conveyance equipment that are configured to avoid exceeding the maximum bending radius of high power optical fibers used with the conveyance structures. There are also provided embodiments of the conveyance structures having channels, lines and passages for delivering materials such as fluids.

This application: (i) claims, under 35 U.S.C. §119(e)(1), the benefit ofthe filing date of Aug. 17, 2010 of provisional application Ser. No.61/374,594; (ii) claims, under 35 U.S.C. §119(e)(1), the benefit of thefiling date of Aug. 31, 2010 of provisional application Ser. No.61/378,910; (iii) claims, under 35 U.S.C. §119(e)(1), the benefit of thefiling date of Feb. 24, 2011 of provisional application Ser. No.61/446,312; (iv) is a continuation-in-part of U.S. patent applicationSer. No. 12/544,136, filed Aug. 19, 2009, which claims, under 35 U.S.C.§119(e)(1), the benefit of the filing date of Aug. 20, 2008 ofprovisional application Ser. No. 61/090,384, the benefit of the filingdate of Oct. 3, 2008 of provisional application Ser. No. 61/102,730, thebenefit of the filing date of Oct. 17, 2008 of provisional applicationSer. No. 61/106,472 and the benefit of the filing date of Feb. 17, 2009of provisional application Ser. No. 61/153,271; (v) is acontinuation-in-part of U.S. patent application Ser. No. 12/544,094,filed Aug. 19, 2009; (vi) is a continuation-in-part of U.S. patentapplication Ser. No. 12/706,576 filed Feb. 16, 2010, which is acontinuation-in-part of U.S. patent application Ser. No. 12/544,136filed Aug. 19, 2009, and which claims, under 35 U.S.C. §119(e)(1), thebenefit of the filing date of Oct. 17, 2008 of provisional applicationSer. No. 61/106,472, the benefit of the filing date of Feb. 17, 2009 ofprovisional application Ser. No. 61/153,271, and the benefit of thefiling date of Jan. 15, 2010 of provisional application Ser. No.61/295,562; (vii) is a continuation-in-part of U.S. patent applicationSer. No. 12/840,978 filed Jul. 21, 2010; and, (viii) claims, under 35U.S.C. §119(e)(1), the benefit of the filing date of Feb. 7, 2011 ofprovisional application Ser. No. 61/439,970, the entire disclosures ofeach of which are incorporated herein by reference.

This invention was made with Government support under Award DE-AR0000044awarded by the Office of ARPA-E U.S. Department of Energy. TheGovernment has certain rights in this invention.

BACKGROUND OF THE INVENTION Field of the Invention

The present inventions relate to the delivery of high power laserenergy. More particularly, the present inventions relate to systems,methods and structures for conveying high power laser energy, alone orin conjunction with other items, such as, data, electricity, gases andliquids, to remote, difficult to access or hazardous locations, such asoil wells, boreholes in the earth, pipelines, underground mines, naturalgas wells, geothermal wells, mining, subsea structures, or nuclearreactors. The high power laser energy and other items may be used at thedelivered location for activities, such as, monitoring, cleaning,controlling, assembling, drilling, machining, powering equipment andcutting.

As used herein, unless specified otherwise “high power laser energy”means a laser beam having at least about 1 kW (kilowatt) of power. Asused herein, unless specified otherwise “great distances” means at leastabout 500 m (meter). As used herein, unless specified otherwise, theterm “substantial loss of power,” “substantial power loss” and similarsuch phrases, mean a loss of power of more than about 3.0 dB/km(decibel/kilometer) for a selected wavelength. As used herein the term“substantial power transmission” means at least about 50% transmittance.

As used herein, unless specified otherwise, “optical connector”, “fiberoptics connector”, “connector” and similar terms should be given theirbroadest possible meaning and include any component from which a laserbeam is or can be propagated, any component into which a laser beam canbe propagated, and any component that propagates, receives or both alaser beam in relation to, e.g., free space, (which would include avacuum, a gas, a liquid, a foam and other non-optical componentmaterials), an optical component, a wave guide, a fiber, andcombinations of the forgoing.

As used herein the term “pipeline” should be given its broadest possiblemeaning, and includes any structure that contains a channel having alength that is many orders of magnitude greater than its cross-sectionalarea and which is for, or capable of, transporting a material along atleast a portion of the length of the channel. Pipelines may be manymiles long and may be many hundreds of miles long. Pipelines may belocated below the earth, above the earth, under water, within astructure, or combinations of these and other locations. Pipelines maybe made from metal, steel, plastics, ceramics, composite materials, orother materials and compositions know to the pipeline arts and may haveexternal and internal coatings, known to the pipeline arts. In general,pipelines may have internal diameters that range from about 2 to about60 inches although larger and smaller diameters may be utilized. Ingeneral natural gas pipelines may have internal diameters ranging fromabout 2 to 60 inches and oil pipelines have internal diameters rangingfrom about 4 to 48 inches. Pipelines may be used to transmit numeroustypes of materials, in the form of a liquid, gas, fluidized solid,slurry or combinations thereof. Thus, for example pipelines may carryhydrocarbons; chemicals; oil; petroleum products; gasoline; ethanol;biofuels; water; drinking water; irrigation water; cooling water; waterfor hydroelectric power generation; water, or other fluids forgeothermal power generation; natural gas; paints; slurries, such asmineral slurries, coal slurries, pulp slurries; and ore slurries; gases,such as nitrogen and hydrogen; cosmetics; pharmaceuticals; and foodproducts, such as beer.

As used herein the term “earth” should be given its broadest possiblemeaning, and includes, the ground, all natural materials, such as rocks,and artificial materials, such as concrete, that are or may be found inthe ground, including without limitation rock layer formations, such as,granite, basalt, sandstone, dolomite, sand, salt, limestone, rhyolite,quartzite and shale rock.

As used herein the term “borehole” should be given it broadest possiblemeaning and includes any opening that is created in a material, a workpiece, a surface, the earth, a structure (e.g., building, protectedmilitary installation, nuclear plant, offshore platform, or ship), or ina structure in the ground, (e.g., foundation, roadway, airstrip, cave orsubterranean structure) that is substantially longer than it is wide,such as a well, a well bore, a well hole, a micro hole, slimhole andother terms commonly used or known in the arts to define these types ofnarrow long passages. Wells would further include exploratory,production, abandoned, reentered, reworked, and injection wells.Although boreholes are generally oriented substantially vertically, theymay also be oriented on an angle from vertical, to and includinghorizontal. Thus, using a vertical line, based upon a level as areference point, a borehole can have orientations ranging from 0° i.e.,vertical, to 90°,i.e., horizontal and greater than 90° e.g., such as aheel and toe, and combinations of these such as for example “U” and “Y”shapes. Boreholes may further have segments or sections that havedifferent orientations, they may have straight sections and arcuatesections and combinations thereof; and for example may be of the shapescommonly found when directional drilling is employed. Thus, as usedherein unless expressly provided otherwise, the “bottom” of a borehole,the “bottom surface” of the borehole and similar terms refer to the endof the borehole, i.e., that portion of the borehole furthest along thepath of the borehole from the borehole's opening, the surface of theearth, or the borehole's beginning. The terms “side” and “wall” of aborehole should to be given their broadest possible meaning and includethe longitudinal surfaces of the borehole, whether or not casing or aliner is present, as such, these terms would include the sides of anopen borehole or the sides of the casing that has been positioned withina borehole. Boreholes may be made up of a single passage, multiplepassages, connected passages and combinations thereof, in a situationwhere multiple boreholes are connected or interconnected each boreholewould have a borehole bottom. Boreholes may be formed in the sea floor,under bodies of water, on land, in ice formations, or in other locationsand settings.

Boreholes are generally formed and advanced by using mechanical drillingequipment having a rotating drilling tool, e.g., a bit. For example andin general, when creating a borehole in the earth, a drilling bit isextending to and into the earth and rotated to create a hole in theearth. In general, to perform the drilling operation the bit must beforced against the material to be removed with a sufficient force toexceed the shear strength, compressive strength or combinations thereof,of that material. Thus, in conventional drilling activity mechanicalforces exceeding these strengths of the rock or earth must be applied.The material that is cut from the earth is generally known as cuttings,e.g., waste, which may be chips of rock, dust, rock fibers and othertypes of materials and structures that may be created by the bit'sinteractions with the earth. These cuttings are typically removed fromthe borehole by the use of fluids, which fluids can be liquids, foams orgases, or other materials know to the art.

As used herein the term “advancing” a borehole should be given itsbroadest possible meaning and includes increasing the length of theborehole. Thus, by advancing a borehole, provided the orientation isless than 90° the depth of the borehole may also increased. The truevertical depth (“TVD”) of a borehole is the distance from the top orsurface of the borehole to the depth at which the bottom of the boreholeis located, measured along a straight vertical line. The measured depth(“MD”) of a borehole is the distance as measured along the actual pathof the borehole from the top or surface to the bottom. As used hereinunless specified otherwise the term depth of a borehole will refer toMD. In general, a point of reference may be used for the top of theborehole, such as the rotary table, drill floor, well head or initialopening or surface of the structure in which the borehole is placed.

As used herein the terms “ream”, “reaming”, a borehole, or similar suchterms, should be given their broadest possible meaning and includes anyactivity performed on the sides of a borehole, such as, e.g., smoothing,increasing the diameter of the borehole, removing materials from thesides of the borehole, such as e.g., waxes or filter cakes, andunder-reaming.

As used herein the terms “drill bit”, “bit”, “drilling bit” or similarsuch terms, should be given their broadest possible meaning and includeall tools designed or intended to create a borehole in an object, amaterial, a work piece, a surface, the earth or a structure includingstructures within the earth, and would include bits used in the oil, gasand geothermal arts, such as fixed cutter and roller cone bits, as wellas, other types of bits, such as, rotary shoe, drag-type, fishtail,adamantine, single and multi-toothed, cone, reaming cone, reaming,self-cleaning, disc, three cone, rolling cutter, crossroller, jet, core,impreg and hammer bits, and combinations and variations of the these.

In both roller cone, fixed bits, and other types of mechanical drillingthe state of the art, and the teachings and direction of the art,provide that to advance a borehole great force should be used to pushthe bit against the bottom of the borehole as the bit is rotated. Thisforce is referred to as weight-on-bit (“WOB”). Typically, tens ofthousands of pounds WOB are used to advance a borehole using amechanical drilling process.

Mechanical bits cut rock by applying crushing (compressive) and/or shearstresses created by rotating a cutting surface against the rock andplacing a large amount of WOB. In the case of a PDC bit this action isprimarily by shear stresses and in the case of roller cone bits thisaction is primarily by crushing (compression) and shearing stresses. Forexample, the WOB applied to an 8¾″ PDC bit may be up to 15,000 lbs, andthe WOB applied to an 8¾″ roller cone bit may be up to 60,000 lbs. Whenmechanical bits are used for drilling hard and ultra-hard rock excessiveWOB, rapid bit wear, and long tripping times result in an effectivedrilling rate that is essentially economically unviable. The effectivedrilling rate is based upon the total time necessary to complete theborehole and, for example, would include time spent tripping in and outof the borehole, as well as, the time for repairing or replacing damagedand worn bits.

As used herein the term “drill pipe” is to be given its broadestpossible meaning and includes all forms of pipe used for drillingactivities; and refers to a single section or piece of pipe. As usedherein the terms “stand of drill pipe,” “drill pipe stand,” “stand ofpipe,” “stand” and similar type terms should be given their broadestpossible meaning and include two, three or four sections of drill pipethat have been connected, e.g., joined together, typically by jointshaving threaded connections. As used herein the terms “drill string,”“string,” “string of drill pipe,” string of pipe” and similar type termsshould be given their broadest definition and would include a stand orstands joined together for the purpose of being employed in a borehole.Thus, a drill string could include many stands and many hundreds ofsections of drill pipe.

As used herein the term “tubular” is to be given its broadest possiblemeaning and includes drill pipe, casing, riser, coiled tube, compositetube, vacuum insulated tubing (“VIT), production tubing and any similarstructures having at least one channel therein that are, or could beused, in the drilling industry. As used herein the term “joint” is to begiven its broadest possible meaning and includes all types of devices,systems, methods, structures and components used to connect tubularstogether, such as for example, threaded pipe joints and bolted flanges.For drill pipe joints, the joint section typically has a thicker wallthan the rest of the drill pipe. As used herein the thickness of thewall of tubular is the thickness of the material between the internaldiameter of the tubular and the external diameter of the tubular.

As used herein, unless specified otherwise the terms “blowoutpreventer,” “BOP,” and “BOP stack” should be given their broadestpossible meaning, and include: (i) devices positioned at or near theborehole surface, e.g., the surface of the earth including dry land orthe seafloor, which are used to contain or manage pressures or flowsassociated with a borehole; (ii) devices for containing or managingpressures or flows in a borehole that are associated with a subsea riseror a connector; (iii) devices having any number and combination ofgates, valves or elastomeric packers for controlling or managingborehole pressures or flows; (iv) a subsea BOP stack, which stack couldcontain, for example, ram shears, pipe rams, blind rams and annularpreventers; and, (v) other such similar combinations and assemblies offlow and pressure management devices to control borehole pressures,flows or both and, in particular, to control or manage emergency flow orpressure situations.

As used herein, unless specified otherwise “offshore” and “offshoredrilling activities” and similar such terms are used in their broadestsense and would include drilling activities on, or in, any body ofwater, whether fresh or salt water, whether manmade or naturallyoccurring, such as for example rivers, lakes, canals, inland seas,oceans, seas, bays and gulfs, such as the Gulf of Mexico. As usedherein, unless specified otherwise the term “offshore drilling rig” isto be given its broadest possible meaning and would include fixedtowers, tenders, platforms, barges, jack-ups, floating platforms, drillships, dynamically positioned drill ships, semi-submersibles anddynamically positioned semi-submersibles. As used herein, unlessspecified otherwise the term “seafloor” is to be given its broadestpossible meaning and would include any surface of the earth that liesunder, or is at the bottom of, any body of water, whether fresh or saltwater, whether manmade or naturally occurring.

As used herein, unless specified otherwise the term “fixed platform,”would include any structure that has at least a portion of its weightsupported by the seafloor. Fixed platforms would include structures suchas: free-standing caissons, well-protector jackets, pylons, bracedcaissons, piled-jackets, skirted piled-jackets, compliant towers,gravity structures, gravity based structures, skirted gravitystructures, concrete gravity structures, concrete deep water structuresand other combinations and variations of these. Fixed platforms extendfrom at or below the seafloor to and above the surface of the body ofwater, e.g., sea level. Deck structures are positioned above the surfaceof the body of water a top of vertical support members that extend downin to the water to the seafloor. Fixed platforms may have a singlevertical support, or multiple vertical supports, e.g., pylons, legs,etc., such as a three, four, or more support members, which may be madefrom steel, such as large hollow tubular structures, concrete, such asconcrete reinforced with metal such as rebar, and combinations of these.These vertical support members are joined together by horizontal andother support members. In a piled-jacket platform the jacket is aderrick-like structure having hollow essentially vertical members nearits bottom. Piles extend out from these hollow bottom members into theseabed to anchor the platform to the seabed.

As used herein the terms “decommissioning,” “plugging” and “abandoning”and similar such terms should be given their broadest possible meaningsand would include activities relating to the cutting and removal ofcasing and other tubulars from a well (above the surface of the earth,below the surface of the earth and both), modification or removal ofstructures, apparatus, and equipment from a site to return the site to aprescribed condition, the modification or removal of structures,apparatus, and equipment that would render such items in a prescribeinoperable condition, the modification or removal of structures,apparatus, and equipment to meet environmental, regulatory, or safetyconsiderations present at the end of such items useful, economical orintended life cycle. Such activities would include for example theremoval of onshore, e.g., land based, structures above the earth, belowthe earth and combinations of these, such as e.g., the removal oftubulars from within a well in preparation for plugging. The removal ofoffshore structures above the surface of a body of water, below thesurface, and below the seafloor and combinations of these, such as fixeddrilling platforms, the removal of conductors, the removal of tubularsfrom within a well in preparation for plugging, the removal ofstructures within the earth, such as a section of a conductor that islocated below the seafloor and combinations of these.

As used herein the terms “workover,” “completion” and “workover andcompletion” and similar such terms should be given their broadestpossible meanings and would include activities that place at or near thecompletion of drilling a well, activities that take place at or the nearthe commencement of production from the well, activities that take placeon the well when the well is producing or operating well, activitiesthat take place to reopen or reenter an abandoned or plugged well orbranch of a well, and would also include for example, perforating,cementing, acidizing, fracturing, pressure testing, the removal of welldebris, removal of plugs, insertion or replacement of production tubing,forming windows in casing to drill or complete lateral or branchwellbores, cutting and milling operations in general, insertion ofscreens, stimulating, cleaning, testing, analyzing and other suchactivities. These terms would further include applying heat, directedenergy, preferably in the form of a high power laser beam to heat, melt,soften, activate, vaporize, disengage, desiccate and combinations andvariations of these, materials in a well, or other structure, to remove,assist in their removal, cleanout, condition and combinations andvariation of these, such materials.

SUMMARY

There has been a long standing need for a system that can deliver highpower directed energy over great distances to small and/or difficult toaccess locations, positions or environments for use in activities suchas monitoring, cleaning, controlling, assembling, drilling, machining,powering equipment, flow assurance and cutting. Such need is present inthe nuclear industry, the chemical industry, the subsea exploration,salvage and construction industry, the pipeline industry, the military,and the oil, natural gas and geothermal industries to name just a few.The present inventions, among other things, solve these and other needsby providing the articles of manufacture, devices and processes taughtherein.

Thus, there is provided herein a a mobile high power laser systemincluding: a laser cabin, the laser cabin housing a high power lasersystem having the capability to general a laser beam having at leastabout 10 kW of power and a wavelength in the range of about 800 nm toabout 2100 nm; a conveyance structure having a length of at least about3,000 feet; the conveyance structure including: a high power opticalfiber having a core diameter of at least about 500 μm and a length of atleast about 3,000 ft, a first support structure having a length of atleast about 3,000 feet, a second support structure having a length of atleast about 3,000 feet, a data or control line having a length of atleast about 3,000 feet, and a passage defined by the first or secondsupport structure, the passage having a length of at least about 3,000feet; and a means for handling the conveyance structure. Still furtherthere is provided this laser system: where the means for handling mayhave an injector; where the means for handling may have a spool and anoptical slip ring; may include a second passage and where the lineprovides electric power; and, including an optical block.

Yet further this is provided a mobile high power laser system including:a laser cabin, the laser cabin housing a high power laser having thecapability to general a laser beam having at least about 10 kW of power;a conveyance structure having a length of at least about 4,000 feet; theconveyance structure including: a high power optical fiber having a corediameter of at least about 300 μm and a length of at least about 4,000feet, an outer support structure having a length of at least about 4,000feet, an inner support structure having a length of at least about 4,000feet, a data or control line having a length of at least about 4,000feet, and a passage defined by the inner or the outer support structure,the passage having a length of at least about 4,000 feet; and a meansfor handling the conveyance structure. This mobile laser system may alsolengths of the optical fiber, the outer support structure, the innersupport structure, the line, and the passage of at least about 5,000feet, and of at least about 10,000 feet, and may also include where themeans for handling has an injector, where the means for handling has aspool and an optical slip ring, where a second passage is included andwherein the line provides electric power, and may also include anoptical block.

Moreover, there is provided a mobile high power laser system including:a base; a means for providing a high power laser beam having at least 5kW of power; a means for containing a handling apparatus; an operatorstation; and, a means for providing electrical power. Additionally, thishigh power system may have the base including a truck chassis, the meansfor providing the high power laser beam having a mobile laser room andwherein the mobile laser room is mounted to the truck chassis; havingthe means for containing the handling apparatus having a handlingapparatus cabin or a handling apparatus bay and having a handlingapparatus including at least about 4,000 feet of a high power conveyancestructure; and wherein the operator station may be controllablyassociated with the mobile laser room and the handling apparatus. Thissystem may also have the base having a trailer; wherein the means forproviding the high power laser beam has a mobile laser room; wherein themeans for containing the handling apparatus has a handling apparatuscabin or a handling apparatus bay, and has a handling apparatusincluding at least about 4,000 feet of a high power conveyance structureand is mounted to the trailer; and wherein the operator booth may becontrollably associated with the mobile laser room and the handlingapparatus.

Yet further, there is provided a mobile high power laser systemincluding: a laser housing; a handling apparatus; a high power lasercapable of generating at least a 10 kW laser beam within the laserhousing; a conveyance structure including a high power optical fiber, apassage, a line and a support structure, wherein the high power opticalfiber having a core diameter of at least about 300 μm and a minimum bendradius; and, an optical block having a radius of curvature, wherein theoptical block radius of curvature is greater than, equal to, or within5% less than the radius of curvature of the high power optical fiber.

There are also provided mobile high power laser systems including atleast 5,000 feet of conveyance structure and where the core diameter maybe at least about 450 μm, where the high power laser is capable ofgenerating a laser beam of at least 20 kW, where the laser housing andthe handling apparatus are associated with a platform, where the laserhousing is associated with a first mobile base and the handlingapparatus is associated with a second mobile base and combinations ofthese.

Additionally there is provided a mobile high power laser systemincluding: a base; the base having a laser housing, an operator housingand a handling apparatus; a chiller, a storage tank, and a laser capableof generating at least a 10 kW laser beam being associated with thelaser housing; a conveyance structure including a high power opticalfiber, a passage, a line and a support structure, wherein the high poweroptical fiber has a minimum bend radius; and, an optical block having aradius of curvature, wherein the optical block radius of curvature isgreater than or substantially equal to the radius of curvature of thehigh power optical fiber.

Additionally, there are provided mobile high power laser systems wherethe conveyance structure is at least 5,000 feet, where the supportstructure of the conveyance structure defines an outer surface for theconveyance structure, where the high power optical fiber is at leastpractically contained within the support structure, where the high poweroptical fiber forms at least a portion of the outer surface for theconveyance structure, where the high power optical fiber and the lineare inside of the support structure, where the wavelength of the laserbeam is from about 800 nm to about 2100 nm, where the wavelength of thelaser beam is from about 1060 nm to about 1800 nm, where the wavelengthof the laser beam is from about 1800 nm to about 2100 nm, including asecond high power optical fiber and a passage, including a plurality oflines, a plurality of high power optical fibers, and a plurality ofsupport structures, where the optical block is associated with the base,where the base is a trailer, where the base is a truck chassis, wherethe base is a skid, where a shipping container defines at least thelaser housing, where the chiller is located within the laser housing andincludes: air intake and exhaust means that may be associated with thechiller and provided in the laser housing, at least one storage tankcomprises a heating element and combinations of these.

There are still further provided herein mobile high power laser systemhaving where the conveyance structure is at least 5,000 feet, theoptical fiber comprises a core having a core diameter of at least about300 μm and the high power laser system comprises a means for suppressinga non-linear effect.

Yet additionally, there are provided mobile high power laser systemsincluding a plurality of lines, a plurality of high power opticalfibers, and a plurality of support structures.

Further still there is provided a high power laser system including: amobile platform; a laser housing associated with the mobile platform; achiller, and a laser capable of generating at least a 10 kW laser beam;at least 1,000 feet of a conveyance structure including a high poweroptical fiber and a protective structure, wherein the high power opticalfiber has a core having a diameter of at least about 300 μm and aminimum bend radius; and, an optical block having a radius of curvature,wherein the optical block radius of curvature is greater than about 3%less than the radius of curvature of the high power optical fiber.

Additionally, there are provided high power laser systems having alaser: that is capable of generating at least a 20 kW laser beam,capable of generating at least a 30 kW laser beam, capable of generatingat least a 50 kW laser beam, where the laser has a first laser capableof providing at least a 5 kW laser beam and a second laser capable ofproviding at least a 5 kW laser, wherein the laser has a plurality oflasers each capable of generating a laser beam having a power so thatthe combined power of the plurality of laser beams is at least about 10kW, at least a 20 kW laser beam, and at least about 50 kW.

Further, there is provided a high power laser system including: a mobileplatform; a laser housing associated with the mobile platform; a lasersystem capable of generating at least a 10 kW laser beam; a conveyancestructure including a high power optical fiber and a protectivestructure, wherein the high power optical fiber has a minimum bendradius; and, the conveyance structure associated with a handlingapparatus for holding and deploying the conveyance structure, whereinthe handling apparatus is configured to maintain the radius of curvaturefor the optical fiber at a radius that is greater than, equal to, orwithin 5% less than the minimum bend radius. This laser system where thehandling apparatus is configured to maintain the radius of curvature forthe conveyance structure at a radius that is at least 1% greater thanthe minimum bend radius, that is at least 2% greater than the minimumbend radius, or that is at least 5% greater than the minimum bendradius.

Moreover there is provided a high power laser system including: a mobileplatform; a laser housing associated with the mobile platform; a lasersystem capable of generating at least a 20 kW laser beam; a laserchiller; a conveyance structure including a high power optical fiber anda support structure, wherein the high power optical fiber has a corehaving a diameter of at least about 300 μm, and a minimum bend radius; ameans for suppressing Stimulated Brillioun Scattering; and, theconveyance structure associated with a handling apparatus for holdingand deploying the conveyance structure, wherein the handling apparatusis configured to maintain the radius of curvature for the conveyancestructure at a radius that is equal to or greater than the minimum bendradius.

Yet still further there is provided a high power laser system deployedat a well site, the system including: a high power laser system capableof generating at least a 10 kW laser beam; a chiller; a conveyancestructure deployment device; an optical block; a conveyance structurehaving a distal end and a proximal end and including a high poweroptical fiber having a minimal bend radius; a lubricator; wherein theproximal end of the conveyance structure is optically associated withthe high power laser and associated with the deployment device; whereinthe conveyance structure is at least practically held by the deploymentdevice and extends from the deployment device to the optical block andextends from the optical block to and into the lubricator, therebydefining a conveyance structure deployment path; wherein the lubricatoris in communication with a well at the well site; and, the conveyancestructure deployment path does not exceed the minimum bend radius forthe optical fiber.

Additionally, there is provided a mobile high power laser system whereinthe conveyance structure comprises: a data line, a passage, a supportstructure and a protective structure and wherein the high power lasersystem comprises a means to suppress a non-linear effect.

Yet additionally there is provided a high power laser system deployed ata well site, the system including: a means for generating a high powerlaser beam having at least a 10 kW of power; a means for deploying aconveyance structure; a conveyance structure having a distal end and aproximal end and including a high power optical fiber having a minimalbend radius and having a core diameter of at least about 300 μm; a meansfor entering a well; wherein the proximal end of the conveyancestructure is optically associated with the high power laser; wherein theconveyance structure is at least practically held by the means fordeploying and extends to and into the means for entering a well, therebydefining a conveyance structure deployment path; wherein the means forentering the well is in communication with a well at the well site; and,the conveyance structure deployment path does not exceed the minimumbend radius for the optical fiber, is at least greater than 5% less thanthe minimum bend radius, or is greater than, equal to, or more than 5%less than the minimum bend radius.

Moreover, there is provided a laser work over and completion unitincluding: a base; a handling apparatus associated with the base; ameans for receiving a laser beam having at least a 5 kW laser beam beingassociated with the handling apparatus; a conveyance structure includinga means for transmitting a laser beam having at least 5 kW of power overat least 3,000 without substantial power loss; a passage, a line and asupport structure, wherein the means for transmitting has a minimum bendradius; and, an optical block having a radius of curvature, wherein theoptical block radius of curvature is is greater than, equal to, orwithin 5% less than the radius of curvature of the means fortransmitting.

Still further there is provided a laser workover and completion systemdeployed at a well site, the system including: a conveyance structuredeployment device; an optical block; a conveyance structure having adistal end and a proximal end and including a high power optical fiberhaving a proximal end and a distal end, and having a minimal bendradius, the proximal end of the high power optical fiber being capableof receiving a high power laser beam and the high power optical fiberbeing capable of transmitting a high power laser beam withoutsubstantial power loss; a lubricator; wherein the proximal end of theconveyance structure is associated with the deployment device; whereinthe conveyance structure is at least practically held by the deploymentdevice and extends from the deployment device to the optical block andextends from the optical block to and into the lubricator, therebydefining a conveyance structure deployment path; wherein the lubricatoris in communication with a well at the well site; and, the conveyancestructure deployment path does not exceed the minimum bend radius forthe optical fiber.

Further yet, there is provided a laser workover and completion systemdeployed at a well site, the system including: a conveyance structuredeployment device; an optical block; a conveyance structure having adistal end and a proximal end and including a high power optical fiberhaving a minimal bend radius; a means for entering a well; wherein theproximal end of the conveyance structure is optically associated withthe high power laser and associated with the deployment device; whereinthe conveyance structure is at least practically held by the deploymentdevice and extends from the deployment device to the optical block andextends from the optical block to and into the means for entering awell, thereby defining a conveyance structure deployment path; whereinthe means for entering the well is in communication with a well at thewell site; and, the conveyance structure deployment path does is greaterthan, equal to, or within 5% less than the minimum bend radius for theoptical fiber.

Moreover there is provided a high power laser conveyance structureincluding: a first layer including a plurality of wound armor wires; asecond layer including a plurality of wound armor wires, wherein thesecond layer is positioned inside of the first layer; the second layerforming a cavity; the cavity containing a high power optical fiber; thehigh power optical fiber including a core and a cladding; the high poweroptical fiber being capable of reducing a non-linear effect when a highpower laser beam is propagated through the optical fiber; and, theconveyance structure being at least 2,000 feet long.

Still further there is provided a high power laser conveyance structureincluding: a support structure; a line associated within the supportstructure; a high power optical fiber associated with the supportstructure; a passage associated with the support structure fortransporting a fluid; and, the high power optical fiber being capable ofreducing a non-linear effect when a high power laser beam is propagatedthrough the optical fiber over distances greater than 2,000 feet.

Yet still further there is provided a high power laser system including:a mobile platform; a laser housing associated with the mobile platform;a laser system capable of generating at least a 10 kW laser beam; aconveyance structure including a high power optical fiber and aprotective structure, wherein the high power optical fiber has a minimumbend radius; and, the conveyance structure associated with a handlingapparatus for holding and deploying the conveyance structure, whereinthe handling apparatus is configured to maintain the radius of curvaturefor the optical fiber at a radius that is more than about 5% less thanthe minimum bend radius.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a transverse cross sectional view, not necessarily to scale,showing the structure of an optical fiber of the present invention.

FIG. 1B is a longitudinal cross sectional view of the optical fiber ofFIG. 1A.

FIG. 2 is a spectrum of laser energy transmitted by the presentinvention showing the absence of SRS phenomena.

FIG. 3 is a schematic view of a mobile laser system of the presentinvention.

FIG. 4 is a schematic diagram for a configuration of lasers of thepresent invention.

FIG. 5 is a schematic diagram for a configuration of laser of thepresent invention.

FIG. 6 is a perspective cutaway of a spool and optical rotatable couplerof the present invention.

FIG. 7 is a schematic diagram of a laser fiber amplifier of the presentinvention.

FIG. 8 is a cross sectional view of a spool of the present invention.

FIGS. 9A and 9B are views of a creel of the present invention.

FIG. 10 is a schematic view of an embodiment of a handling apparatus ofthe present invention.

FIG. 11 is a schematic view of an embodiment of a handling apparatus ofthe present invention.

FIG. 12A to 12C are perspective views and a schematic cross sectionalview, respectively, of an embodiment of a handling apparatus of thepresent invention.

FIG. 13 is a schematic view of a mobile laser system and control systemof the present invention.

FIGS. 14, 15, 16, 17, 18, 19, 20A and 20B, 21, 22, 23, 24, 25, 26, 33and 34 are schematic views of conveyance structures of the presentinvention.

FIG. 27A is a perspective view of a mobile high power laser system ofthe present invention.

FIG. 27B is a plan schematic view of the components of a section of thesystem of FIG. 27A.

FIG. 27C is longitudinal cross sectional view of the system of FIG. 27A.

FIG. 27D is a schematic view of the system of FIG. 27A deployed at awell site.

FIG. 28 is a schematic view of a mobile high power laser system having abay for holding a conveyance structure of the present invention.

FIG. 29 is a perspective view of a mobile conveyance system of thepresent invention.

FIG. 30 is a perspective view of a mobile conveyance system of thepresent invention.

FIG. 31 is a perspective schematic view of a mobile high power lasersystem of the present invention.

FIG. 32A is a plan schematic view of a mobile high power laser system ofthe present invention.

FIG. 32B is a side view of the system of FIG. 32A.

FIG. 32C is a rear view of the system of FIG. 32A.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present inventions relate to the delivery of high power laser energyand particularly to systems, methods and structures for conveying highpower laser energy, alone or in conjunction with other items, such as,data, electricity, gases and liquids, for use with tools, equipment orin activities such as monitoring, drilling, cleaning, controlling,assembling, machining, powering equipment and cutting.

Thus, and in general, there are provided high power laser systems, whichmay include, conveyance structures for use in delivering high powerlaser energy over great distances and to work areas where the high powerlaser energy may be utilized. Preferably, the system may include one ormore high power lasers, which are capable of providing: one high powerlaser beam, a single combined high power laser beam, multiple high powerlaser beams, which may or may not be combined at various point orlocations in the system, or combinations and variations of these.

A single high power laser may be utilized in the system, or the systemmay have two or three high power lasers, or more. High power solid-statelasers, specifically semiconductor lasers and fiber lasers arepreferred, because of their short start up time and essentiallyinstant-on capabilities. The high power lasers for example may be fiberlasers or semiconductor lasers having 10 kW, 20 kW, 50 kW or more powerand, which emit laser beams with wavelengths in the range from about 455nm (nanometers) to about 2100 nm, preferably in the range about 800 nmto about 1600 nm, about 1060 nm to 1080 nm, 1530 nm to 1600 nm, 1800 nmto 2100 nm, and more preferably about 1064 nm, about 1070-1080 nm, about1360 nm, about 1455 nm, 1490 nm, or about 1550 nm, or about 1900 nm(wavelengths in the range of 1900 nm may be provided by Thulium lasers).

For example a preferred type of fiber laser would be one that includes20 modules or more. The gain bandwidth of a fiber laser is on the orderof 20 nm, the linewidth of the free oscillator is 3 nm, Full Width HalfMaximum (FWHM) and may range from 3 nm to 5 nm (although higherlinewidths including 10 nm are envisioned and contemplated). Eachmodule's wavelength is slightly different. The modules further eachcreate a multi-mode beam. Thus, the cumulative effect of combining thebeams from the modules is to maintain the Raman gain and the Brillouingain at a lower value corresponding to the wavelengths and linewidths ofthe individual modules, and thus, consequently reducing the SBS and SRSphenomenon in a fiber when the combined beams are transmitted throughthe fiber. An example of this general type of fiber laser is the IPGYLR-20000. The detailed properties of which are disclosed in US patentapplication Publication Number 2010/0044106.

In some embodiments, a fiber laser emitted light at wavelengthscomprised of 1060 nm to 1080 nm, 1530 nm to 1600 nm, 1800 nm to 2100 nm,diode lasers from 400 nm to 1600 nm, CO₂ Laser at 10,600 nm (however,CO₂ laser do not couple into conventional fused silica optical fibersand thus a solid fiber capable of transmitting these wavelengths, orhollow light pipe or later developed optical means may be utilized totransmit this laser beam), or Nd:YAG Laser emitting at 1064 nm cancouple to the optical fibers. In some embodiments, the fiber can have alow water content. Preferably, the water content of the fiber should beas low as is possible.

Examples of preferred lasers, and in particular solid-state lasers, suchas fibers lasers, are set forth in US Patent Application PublicationNumbers 2010/0044106, 2010/0044105 and 2010/0215326 and in pending U.S.patent application Ser. No. 12/840,978, the entire disclosures of eachof which are incorporated herein by reference. Further diode lasers, andfor example, such lasers having a wavelength of from about 0.9 micronsto 2 microns may be utilized.

In general, the system may also include one or more mobile laserstructures, which could be, for example: an integrated laser wirelinetruck; a laser coiled tubing rig; a laser power spool and transmissioncable; an integrated laser workover and completion unit; or other mobileor movable structures, such as integrated wheeled structures, trailers,semi-trailer, skids, shipping containers, rail cars or carriages, orsimilar equipment. Although a fixed laser structure may be employed, forexample at a sight where the laser may be used for a longer term period,such as the decommissioning of a large facility. The mobile laserstructures houses, or has a laser cabin that houses, the high powerlaser(s), and may further be specifically constructed to protect thelaser from specifically anticipated environment conditions, such asdesert conditions, off-shore conditions, arctic conditions, and otherenvironmental conditions that may be present throughout the world, or itmay be constructed to protect the laser against the general and variedtypes of weather and environmental conditions that are encountered atoilfield sites throughout the world. The mobile laser structure may alsohave the support systems for the operation of the laser, such as achiller, electric generators, beam switches, beam combiners,controllers, computers and other types of laser support, control ormonitoring systems.

The mobile laser structure may also have, integral with, as a part of,as a separate mobile structure, or as a combination or variations ofthese, a high power laser conveyance structure and a handling apparatusfor that structure. The handling apparatus may include, or be, a spool,a creel, reverse loop structures that do not twist the fiber, an opticalslip ring, a figure-eight wrapping structure, and other structures andequipment for the handling of long tubing, cables, wires or fibers. Thehandling apparatus should be selected, constructed or configured toavoid, minimize or manage, transmission losses that may occur frommacro-bending, micro-bending, strain or other physical, optical oropto-physical phenomena that may occur when a high power optical fiberis wound and unwound or otherwise paid out and retrieved. Thus, forexample, it is preferable to avoid placing the fiber in a tighter, i.e.,smaller, bend radius, than the fiber manufacture's specified minimumbend radius. More preferably, the fiber should be configured anddeployed to avoid having any radius of curvature that is within 1% ofthe minimum bend radius to provide a margin of error during operations.In general the minimum bend radius is the minimum radius of curvature toavoid a predetermined stress level for a particular fiber. Thus, it ispreferred that the radii of curvature in the system be equal to orgreater than the minimum bend radius, however, they may be 1% tighter,2% tighter and about 5% tighter, provided that losses and stress induceddetrimental effects do not substantially adversely effect the desiredperformance of the system in an intended application. Moreover,techniques, methods and configurations to avoid, minimize, or managesuch losses are provided in U.S. patent application Ser. No. 12/840,978filed Jul. 21, 2010, the entire disclosure of which is incorporatedherein by reference.

The handling apparatus may also include a drive, power or rotatingmechanism for paying out or retrieving the conveyance structure. Thismechanism may be integral with the mobile laser structure and configuredto receive and handle different conveyance structures; for example, alaser wire line truck, having a bay to receive different sizes ofspools, spools having different conveyance structures, or both. Thedrive, power or rotating mechanism may be integral with the mobile laserstructure. And, this mechanism may be operably associated with themobile laser structure in other manners.

Thus, the conveyance structure may be: a single high power opticalfiber; it may be a single high power optical fiber that has shielding;it may be a single high power optical fiber that has multiple layers ofshielding; it may have two, three or more high power optical fibers thatare surrounded by a single protective layer, and each fiber mayadditionally have its own protective layer; it may contain or haveassociated with the fiber a support structure which may be integral withor releasable or fixedly attached to optical fiber (e.g., a shieldedoptical fiber is clipped to the exterior of a metal cable and lowered bythe cable into a borehole); it may contain other conduits such as aconduit to carry materials to assist a laser cutter, for example gas,air, nitrogen, oxygen, inert gases; it may have other optical or metalfiber for the transmission of data and control information and signals;it may be any of the combinations and variations thereof.

The conveyance structure transmits high power laser energy from thelaser to a location where high power laser energy is to be utilized or ahigh power laser activity is to be performed by, for example, a highpower laser tool. The conveyance structure may, and preferably in someapplications does, also serve as a conveyance device for the high powerlaser tool. The conveyance structure's design or configuration may rangefrom a single optical fiber, to a simple to complex arrangement offibers, support cables, shielding on other structures, depending uponsuch factors as the environmental conditions of use, performancerequirements for the laser process, safety requirements, toolrequirements both laser and non-laser support materials, toolfunction(s), power requirements, information and data gathering andtransmitting requirements, control requirements, and combinations andvariations of these.

Preferably, the conveyance structure may be coiled tubing, a tube withinthe coiled tubing, jointed drill pipe, jointed drill pipe having a pipewithin a pipe, or may be any other type of line structure, that has ahigh power optical fiber associated with it. As used herein the term“line structure” should be given its broadest meaning, unlessspecifically stated otherwise, and would include without limitation:wireline; coiled tubing; slick line; logging cable; cable structuresused for completion, workover, drilling, seismic, sensing, and logging;cable structures used for subsea completion and other subsea activities;umbilicals; cables structures used for scale removal, wax removal, pipecleaning, casing cleaning, cleaning of other tubulars; cables used forROV control power and data transmission; lines structures made fromsteel, wire and composite materials, such as carbon fiber, wire andmesh; line structures used for monitoring and evaluating pipeline andboreholes; and would include without limitation such structures as Power& Data Composite Coiled Tubing (PDT-COIL) and structures such as SmartPipe® and FLATpak®.

High powered conveyance structures and handling apparatus are disclosedin US Patent Application Publications 2010/0044106, 2010/0044105 and2010/0215326 and in pending U.S. patent application Ser. No. 12/840,978,the entire disclosures of each of which are incorporated herein byreference.

High power long distance laser fibers, which are disclosed in detail inUS Patent Application Publications 2010/0044106, 2010/0044105 and2010/0215326 and in pending U.S. patent application Ser. No. 12/840,978,the entire disclosures of each of which are incorporated herein byreference, break the length-power-paradigm, and advance the art of highpower laser delivery beyond this paradigm, by providing optical fibersand optical fiber cables (which terms are used interchangeably hereinand should be given their broadest possible meanings, unless specifiedotherwise), which may be used as, in association with, or as a part ofconveyance structures, that overcome these and other losses, broughtabout by nonlinear effects, macro-bending losses, micro-bending losses,stress, strain, and environmental factors and provides for thetransmission of high power laser energy over great distances withoutsubstantial power loss.

An example of an optical fiber cable for transmitting high power laserenergy over great distances is a cable having a length that is greaterthan about 0.5 km, greater than 2 km greater than about 3 km or greaterthan about 5 km; the cable is a layered structure comprising: a core; acladding; a coating; a first protective layer; and, a second protectivelayer, the cable is capable of transmitting laser energy having a powergreater than or equal to about 1 kW, about 5 kW or about 10 kW, over thelength of the cable with a power loss of less than about 2 dB/km andpreferably less than about 1 dB/km and more preferably less than about0.3 dB/km for a selected wavelength. This cable may also be capable ofproviding laser energy to a tool or surface; the laser energy having aspectrum, such that the laser energy at the delivery location issubstantially free from SRS and SBS phenomena. Fiber cables may havelengths that are greater than 0.5 km, greater than about 1 km, greaterthan about 2 km, greater than about 3 km, or greater.

For example an optical fiber cable may be an optical fiber in astainless steel metal tube, the tube having an outside diameter of about⅛″ (“inch”). The optical fiber having a core diameter of about 600 μm,(microns), about 1000 μm, and from about 600-1000 μm, a claddingthickness of about 50 μm, (the thickness of a layer or coating ismeasured from the internal diameter or inner surface of the layer orcoating to the outer diameter or outer surface of the layer or coating)and an acrylate coating thickness of about 100 μm. The optical fiber maybe within a TEFLON sleeve, that is within the stainless steel tube.

Single and multiple optical fiber cables and optical fibers may beutilized, or a single optical cable with multiple optical fibers may beutilized; thus for example an optical-fiber squid may be used, a beamcombiner may be used, or other assemblies to combine multiple fibersinto a single fiber may be used, as part of, or in conjunction with thelaser systems and conveyance structures of the present invention.Although the use of single length of fiber, i.e., the length of fiber ismade up of one fiber rather than a series of fibers coupled, spliced orotherwise optically affixed end to end, for the longer distance powertransmission is preferred, the use of multiple lengths of fiber joinedend to end may be utilized. Moreover, several lengths of the opticalfiber cables, or several lengths of fiber core structures, orcombinations of both, may be joined into a plurality of such structures,such as in a bundle of optical fiber cables, fiber core structures orcombinations of both.

Large core optical fibers are utilized with the present systems andconveyance structures to provide for the transmission of high powerlaser energy over great distances. Thus, configurations having a corediameter equal to or greater than 50 microns, equal to or greater than75 microns and most preferably equal to or greater than 100 microns, ora plurality of optical fibers utilized. These optical fibers areprotected by a protective structure(s), which may be independent of,integral with, provided by, or associated with, the conveyancestructure.

For example, each optical fiber may have a carbon coating, a polymer,and may include TEFLON coating to cushion the optical fibers whenrubbing against each other during deployment. Thus the optical fiber, orbundle of optical fibers, can have a diameter of from about greater thanor equal to 150 microns to about 700 microns, 700 microns to about 1.5mm, or greater than 1.5 mm.

The fibers may have a buffer or jacket coatings that may includepreferably tefzel, or teflon, or another fluoropolymer or similarmaterials which have significant transmission at the desired wavelength,and substantial temperature capability for the selected application.

The carbon coating, is less preferred and finds applications in avoidinghydrogen effects and can range in thicknesses from 10 microns to >600microns. The polymer or TEFLON coating can range in thickness from 10microns to >600 microns and preferred types of such coating areacrylate, silicone, polyimide, PFA and others. The carbon coating can beadjacent the optical fiber, with the polymer or TEFLON coating beingapplied to it. Polymer, TEFLON, or other coatings are generally appliedlast to reduce binding of the optical fibers during deployment.

In some non-limiting embodiments, fiber optics may handle or transmit upto 10 kW per an optical fiber, up to 20 kW per an optical fiber, up toand greater than 50 kW per optical fiber. The optical fibers maytransmit any desired wavelength or combination of wavelengths. In someembodiments, the range of wavelengths the optical fiber can transmit maypreferably be between about 800 nm and 2100 nm. The optical fiber can beconnected by a connector to another optical fiber to maintain the properfixed distance between one optical fiber and neighboring optical fibers.The optical fibers may also be spliced end-to-end to increase theoverall length of the uninterrupted optical fiber.

For example, optical fibers can be connected such that the beam spotfrom neighboring optical fibers when irradiating the material, such as arock surface or casing to be cut are under 2″ and non-overlapping to theparticular optical fiber. The optical fiber may have any desired coresize. In some embodiments, the core size may range from about 50 micronsto 1 mm or greater and preferably is about 500 microns to about 1000microns. The optical fiber can be single mode or multimode. Ifmultimode, the numerical aperture of some embodiments may range from 0.1to 0.6. A lower numerical aperture may be preferred for beam quality,and a higher numerical aperture may be easier to transmit higher powerswith lower interface losses. In some embodiments, a fiber laser emittedlight at wavelengths comprised of 1060 nm to 1080 nm, 1530 nm to 1600nm, 1800 nm to 2100 nm, diode lasers from 800 nm to 2100 nm, or Nd:YAGLaser emitting at 1064 nm can couple to the optical fibers. In someembodiments, the optical fiber can have a low water content. The opticalfiber can be jacketed, as a part of the conveyance structure orindependently, such as with polyimide, acrylate, carbon polyamide, andcarbon/dual acrylate or other material. If requiring high temperatures,a polyimide or a derivative material may be used to operate attemperatures over 300 C.°. The optical fibers can be a hollow corephotonic crystal or solid core photonic crystal. In some embodiments,using hollow core photonic crystal fibers at wavelengths of 1500 nm orhigher may minimize absorption losses (however, at present these fibershave drawbacks in that higher power connectors are not readily availableand thus would require the system to be optically associated without theuse of connectors). Additionally, Zirconium Fluoride (ZrF₄), Halidefibers, Fluoride glass fibers (e.g., Calcium Fluoride etc.) and activefibers may be utilized.

The use of the plurality of optical fibers can be bundled into a numberof configurations to improve power density. The optical fibers forming abundle may range from two at hundreds of watts to kilowatt powers ineach optical fiber to millions at milliwatts or microwatts of power. Insome embodiments, the plurality of optical fibers may be bundled andspliced at powers below 2.5 kW to step down the power. Power can bespliced to increase the power densities through a bundle, such aspreferably up to 10 kW, more preferably up to 20 kW, and even morepreferably up to or greater than 50 kW. The step down and increase ofpower allows the beam spot to increase or decrease power density andbeam spot sizes through the fiber optics. In most examples, splicing thepower to increase total power output may be beneficial so that powerdelivered through optical fibers does not reach past the critical powerthresholds for fiber optics.

Thus, by way of example there is provided the following configurationsset forth in Table 1 herein.

TABLE 1 Diameter of bundle Number of fibers in bundle 100 microns 1 200microns-1 mm 2 to 100 100 microns-1 mm 1

A thin wire may also be packaged, for example in the ¼″ stainlesstubing, along with the optical fibers to test the optical fiber forcontinuity. Alternatively a metal coating of sufficient thickness isapplied to allow the optical fiber continuity to be monitored. Theseapproaches, however, become problematic as the optical fiber exceeds 1km in length, and do not provide a practical method for testing andmonitoring. Other examples of continuity monitory, break detection andfiber monitoring systems and apparatus are provided in U.S. PatentApplication Ser. No. 61/446,407, the entire disclosure of which isincorporated herein by reference.

The configurations in Table 1, as well as other configurations, can beof lengths equal to or greater than 1 m, equal to or greater than 1 km,equal to or greater than 2 km, equal to or greater than 3 km, equal toor greater than 4 km and equal to or greater than 5 km. Theseconfigurations can be used to transmit power levels from about 0.5 kW toabout 10 kW, from greater than or equal to 1 kW, greater than or equalto 2 kW, greater than or equal to 5 kW, greater than or equal to 8 kW,greater than or equal to 10 kW and preferable at least about 20 kW.

In transmitting power over long distances, such as down a borehole orthrough a cable that is at least 1 km, there are in general threesources of power losses from non-linear effects in an optical fiber,Raleigh Scattering, Raman Scattering and Brillioun Scattering. Thefirst, Raleigh Scattering is the intrinsic losses of the optical fiberdue to the impurities in the optical fiber. The second, Raman Scatteringcan result in Stimulated Raman Scattering in a Stokes or Anti-Stokeswave off of the vibrating molecules of the optical fiber. RamanScattering occurs preferentially in the forward direction and results ina wavelength shift of up to +25 nm from the original wavelength of thesource. The third mechanism, Brillioun Scattering, is the scattering ofthe forward propagating pump off of the acoustic waves in the opticalfiber created by the high electric fields of the original source light(pump). This third mechanism is highly problematic and may create greatdifficulties in transmitting high powers over long distances. TheBrillioun Scattering can give rise to Stimulated Brillioun Scattering(SBS) where the pump light is preferentially scattered backwards in theoptical fiber with a frequency shift of approximately 1 to about 20 GHzfrom the original source frequency. This Stimulated Brillioun effect canbe sufficiently strong to backscatter substantially all of the incidentpump light if given the right conditions. Therefore it is desirable tosuppress this non-linear phenomenon. There are essentially four primaryvariables that determine the threshold for SBS: the length of the gainmedium (the optical fiber); the linewidth of the source laser; thenatural Brillioun linewidth of the optical fiber the pump light ispropagating in; and, the mode field diameter of the optical fiber. Undertypical conditions and for typical optical fibers, the length of theoptical fiber is inversely proportional to the power threshold, so thelonger the optical fiber, the lower the threshold. The power thresholdis defined as the power at which a high percentage of incident pumpradiation will be scattered such that a positive feedback takes placewhereby acoustic waves are generated by the scattering process. Theseacoustic waves then act as a grating to incite further SBS. Once thepower threshold is passed, exponential growth of scattered light occursand the ability to transmit higher power is greatly reduced. Thisexponential growth continues with an exponential reduction in poweruntil such point whereby any additional power input will not betransmitted forward which point is defined herein as the maximumtransmission power. Thus, the maximum transmission power is dependentupon the SBS threshold, but once reached, the maximum transmission powerwill not increase with increasing power input.

Thus, as provided herein, novel and unique means for suppressingnonlinear scattering phenomena, such as the SBS and Stimulated RamanScattering phenomena, means for increasing power threshold, and meansfor increasing the maximum transmission power are set forth for use intransmitting high power laser energy over great distances for, amongother things, the advancement of boreholes.

The mode field diameter needs to be as large as practical withoutcausing undue attenuation of the propagating source laser. Large coresingle mode optical fibers are currently available with mode diametersup to 30 microns, however bending losses are typically high andpropagation losses are higher than desired. Small core step indexoptical fibers, with mode field diameters of 50 microns are of interestbecause of the low intrinsic losses, the significantly reduced fluence,the decreased SBS gain, a non-polarization preserving design, and, amulti-mode propagation constant. All of these factors effectivelyincrease the SBS power threshold. Consequently, a larger core opticalfiber with low Raleigh Scattering losses is a solution for transmittinghigh powers over great distances, preferably where the mode fielddiameter is 50 microns or greater in diameter.

The next consideration is the natural Brillioun linewidth of the opticalfiber. As the Brillioun linewidth increases, the scattering gain factordecreases. The Brillioun linewidth can be broadened by varying thetemperature along the length of the optical fiber, modulating the strainon the optical fiber and inducing acoustic vibrations in the opticalfiber. Varying the temperature along the optical fiber results in achange in the index of refraction of the optical fiber and thebackground (kT) vibration of the atoms in the optical fiber effectivelybroadening the Brillioun spectrum. In down borehole application thetemperature along the optical fiber will vary naturally as a result ofthe geothermal energy that the optical fiber will be exposed to at thedepths, and ranges of depths, expressed herein. The net result will be asuppression of the SBS gain. Applying a thermal gradient along thelength of the optical fiber could be a means to suppress SBS byincreasing the Brillioun linewidth of the optical fiber. For example,such means could include using a thin film heating element or variableinsulation along the length of the optical fiber to control the actualtemperature at each point along the optical fiber. Applied thermalgradients and temperature distributions can be, but are not limited to,linear, step-graded, and non-periodic functions along the length of theoptical fiber.

Modulating the strain for the suppression of nonlinear scatteringphenomena, on the optical fiber can be achieved, but those means are notlimited to anchoring the optical fiber in its jacket in such a way thatthe optical fiber is strained. By stretching each segment betweensupport elements selectively, then the Brillioun spectrum will eitherred shift or blue shift from the natural center frequency effectivelybroadening the spectrum and decreasing the gain. If the optical fiber isallowed to hang freely from a tensioner, then the strain will vary fromthe top of the hole to the bottom of the hole, effectively broadeningthe Brillioun gain spectrum and suppressing SBS. Means for applyingstrain to the optical fiber include, but are not limited to, twistingthe optical fiber, stretching the optical fiber, applying externalpressure to the optical fiber, and bending the optical fiber. Thus, forexample, as discussed above, twisting the optical fiber can occurthrough the use of a creel. Moreover, twisting of the optical fiber mayoccur through use of downhole stabilizers designed to provide rotationalmovement. Stretching the optical fiber can be achieved, for example asdescribed above, by using support elements along the length of theoptical fiber. Downhole pressures may provide a pressure gradient alongthe length of the optical fiber thus inducing strain.

Acoustic modulation of the optical fiber can alter the Brilliounlinewidth. By placing acoustic generators, such as piezo crystals alongthe length of the optical fiber and modulating them at a predeterminedfrequency, the Brillioun spectrum can be broadened, effectivelydecreasing the SBS gain. For example, crystals, speakers, mechanicalvibrators, or any other mechanism for inducing acoustic vibrations intothe optical fiber may be used to effectively suppress the SBS gain.Additionally, acoustic radiation can be created by the escape ofcompressed air through predefined holes, creating a whistle effect.

A spectral beam combination of laser sources may be used to suppressStimulated Brillioun Scattering. Thus the spaced wavelength beams, thespacing as described herein, can suppress the Stimulated BrilliounScattering through the interference in the resulting acoustic waves,which will tend to broaden the Stimulated Brillioun Spectrum and thusresulting in lower Stimulated Brillioun Gain. Additionally, by utilizingmultiple colors the total maximum transmission power can be increased bylimiting SBS phenomena within each color. An example of such a lasersystem is illustrated in FIG. 4.

For example, FIG. 4 Illustrates a spectral beam combination of laserssources to enable high power transmission down a fiber by allocating apredetermined amount of power per color as limited by the StimulatedBrillioun Scattering (SBS) phenomena. Thus, there is provided in FIG. 4a first laser source 401 having a first wavelength of “x”, where x maypreferably be less than 1 micron, but may also be 1 micron and larger.There is provided a second laser 402 having a second wavelength of x+δ1microns, where δ1 is a predetermined shift in wavelength, which shiftcould be positive or negative. There is provided a third laser 403having a third wavelength of x+δ1+δ2 microns and a fourth laser 404having a wavelength of x+δ1+δ2+δ3 microns. The laser beams are combinedby a beam combiner 405 and transmitted by an optical fiber 406. Thecombined beam having a spectrum shown in 407.

The interaction of the source linewidth and the Brillioun linewidth inpart defines the gain function. Varying the linewidth of the source cansuppress the gain function and thus suppress nonlinear phenomena such asSBS. The source linewidth can be varied, for example, by FM modulationor closely spaced wavelength combined sources, an example of which isillustrated in FIG. 5. Thus, a fiber laser can be directly FM modulatedby a number of means, one method is simply stretching the fiber with apiezo-electric element which induces an index change in the fibermedium, resulting in a change in the length of the cavity of the laserwhich produces a shift in the natural frequency of the fiber laser. ThisFM modulation scheme can achieve very broadband modulation of the fiberlaser with relatively slow mechanical and electrical components. A moredirect method for FM modulating these laser sources can be to pass thebeam through a non-linear crystal such as Lithium Niobate, operating ina phase modulation mode, and modulate the phase at the desired frequencyfor suppressing the gain.

FIG. 5. Illustrates a frequency modulated array of lasers. Thus, thereis provided a master oscillator than can be frequency modulated,directly or indirectly, that is then used to injection-lock lasers oramplifiers to create a higher power composite beam than can be achievedby any individual laser. Thus, there are provided lasers 501, 502, 503,and 504, which have the same wavelength. The laser beams are combined bya beam combiner 505 and transmitted by an optical fiber 506. The lasers501, 502, 503 and 504 are associated with a master oscillator 508 thatis FM modulated. The combined beam having a spectrum show in 507, whereδ is the frequency excursion of the FM modulation. Such lasers aredisclosed in U.S. Pat. No. 5,694,408, the disclosure of which isincorporated here in reference in its entirety.

Raman scattering can be suppressed by the inclusion of awavelength-selective filter in the optical path. This filter can be areflective, transmissive, or absorptive filter. Moreover, an opticalfiber connector can include a Raman rejection filter. Additionally aRaman rejection filter could be integral to the optical fiber. Thesefilters may be, but are not limited to, a bulk filter, such as adichroic filter or a transmissive grating filter, such as a Bragggrating filter, or a reflective grating filter, such as a ruled grating.For any backward propagating Raman energy, as well as, a means tointroduce pump energy to an active fiber amplifier integrated into theoverall optical fiber path, is contemplated, which, by way of example,could include a method for integrating a rejection filter with a couplerto suppress Raman Radiation, which suppresses the Raman Gain. Further,Brillioun scattering can be suppressed by filtering as well. Faradayisolators, for example, could be integrated into the system. A BraggGrating reflector tuned to the Brillioun Scattering frequency, with asingle frequency laser source and with the laser locked to apredetermined wavelength could also be integrated into the coupler tosuppress the Brillioun radiation.

To overcome power loss in the optical fiber as a function of distance,active amplification of the laser signal can be used. An active fiberamplifier can provide gain along the optical fiber to offset the lossesin the optical fiber. For example, by combining active fiber sectionswith passive fiber sections, where sufficient pump light is provided tothe active, i.e., amplified section, the losses in the passive sectionwill be offset. Thus, there is provided a means to integrate signalamplification into the system. In FIG. 7 there is illustrated an exampleof such a means having a first passive fiber section 700 with, forexample, −1 dB loss, a pump source 701 optically associated with thefiber amplifier 702, which may be introduced into the outer clad, toprovide for example, a +1 dB gain of the propagating signal power. Thefiber amplifier 702 is optically connected to a coupler 703, which canbe free spaced or fused, which is optically connected to a passivesection 704. This configuration may be repeated numerous times, forvarying lengths, power losses, and downhole conditions. Additionally,the fiber amplifier could act as the delivery optical fiber for theentirety of the transmission length. The pump source may be uphole,downhole, or combinations of uphole and downhole for various boreholeconfigurations.

A further method is to use dense wavelength beam combination of multiplelaser sources to create an effective linewidth that is many times thenatural linewidth of the individual laser effectively suppressing theSBS gain. Here multiple lasers each operating at a predeterminedwavelength and at a predetermined wavelength spacing are superimposed oneach other, for example by a grating. The grating can be transmissive orreflective.

Mode field variation as a function of length, index of refraction as afunction of length, core size variation as a function of length, thefusing of different types or specifications for fibers together,altering the gain spectrum of the fiber, altering the spectrum of thelaser, the pulsing of the laser at shorter time durations than the timeconstant of the phonon propagation in the fiber, are methodologies, thatmay be utilized in in combination with each other, and in combinationwith, a lone, or in addition to, other methodologies provided in thisspecification to suppresses or reduce non-liner effects.

The optical fiber or fiber bundle can be: encased in a separate shieldor protective layer; or incorporated in or associated with a conveyancestructure; or both, to shield the optical fiber and to enable it tosurvive at high pressures and temperatures. The cable could be similarin construction to the submarine cables that are laid across the oceanfloor and may be buoyant, or have neutral buoyancy, if the borehole isfilled with water. The cable may include one or many optical fibers inthe cable, depending on the power handling capability of the opticalfiber and the power required to achieve economic drilling rates. Itbeing understood that in the field several km of optical fiber may haveto be delivered down the borehole. The fiber cables may be made invarying lengths such that shorter lengths are used for shallower depthsso higher power levels can be delivered and consequently higher drillingrates can be achieved. This method requires the optical fibers to bechanged out when transitioning to depths beyond the length of the fibercable. Alternatively a series of connectors could be employed if theconnectors could be made with low enough loss to allow connecting andreconnecting the optical fiber(s) with minimal losses.

Thus, there is provided in Tables 2 and 3 herein power transmissions forexemplary optical cable configurations.

TABLE 2 Power Length Diameter # of fibers Power in of fiber(s) of bundlein bundle out 20 kW 5 km 500 microns 1 15 kW 20 kW 7 km 500 microns 1 13kW 20 kW 5 km 650 micron 1 15 kW 20 kW 5 km   1 mm 1 15 kW 20 kW 7 km1.05 mm 1 13 kW 20 kW 5 km 200 microns-1 mm 2 to 100 12-15 kW 20 kW 7 km200 microns-1 mm 2 to 100  8-13 kW 20 kW 5 km 100-200 microns 1 10 kW 20kW 7 km 100-200 microns 1  8 kW

TABLE 3 (with active amplification) Power Length Diameter # of fibersPower in of fiber(s) of bundle in bundle out 20 kW 5 km 500 microns 1 20kW 20 kW 7 km 500 microns 1 20 kW 20 kW 5 km 200 microns-1 mm 2 to 10020 kW 20 kW 7 km 200 microns-1 mm 2 to 100 20 kW 20 kW 5 km 100-200microns 1 20 kW 20 kW 7 km 100-200 microns 1 20 kW

The optical fibers may be placed inside of or associated with aconveyance structure such as a coiled tubing, line structure, orcomposite tubular structure for advancement into and removal from theborehole. In this manner the line structure or tubing would be theprimary load bearing and support structure as the assembly is loweredinto the well. It can readily be appreciated that in wells of greatdepth the tubing will be bearing a significant amount of weight becauseof its length. In configurations where the optical fiber is locatedinside of an open passage or channel in the tube, as opposed to beingintegral with, fixed to, or otherwise associated with the side wall ofthe tube, to protect and secure the optical fibers, including theoptical fiber bundle contained in the, for example, ¼″ or ⅛″ or similarsize stainless steel tubing, inside the coiled tubing stabilizationdevices may be desirable. Thus, at various intervals along the length ofthe tubing supports can be located inside the tubing that fix or holdthe optical fiber in place relative to the tubing. These supports,however, should not interfere with, or otherwise obstruct, the flow offluid, if fluid is being transmitted through the tubing. An example of acommercially available stabilization system is the ELECTROCOIL System.These support structures, as described above, may be used to providestrain to the optical fiber for the suppression of nonlinear phenomena.

The optical fibers may also be associated with the tubing by, forexample, being run parallel to the tubing, and being affixed thereto, bybeing run parallel to the tubing and be slidably affixed thereto, or bybeing placed in a second tubing that is associated or not associatedwith the first tubing. In this way, it should be appreciated thatvarious combinations of tubulars may be employed to optimize thedelivery of laser energy, fluids, and other cabling and devices into theborehole. Moreover, the optical fiber may be segmented and employed withconventional strands of drilling pipe and thus be readily adapted foruse with a conventional mechanical drilling rig outfitted withconnectable tubular drill pipe, or it may be associated with theexterior of the drill pipe as the pipe is tripped into the well (andcorrespondingly disassociated from the pipe as it is tripped out of thewell).

For example, and in general, there is provided in FIGS. 1A and 1B anoptical fiber cable having a core 1, a cladding 2, a coating 3, a firstprotective layer 4, and a second protective layer 5. Although shown inthe figures as being concentric, it is understood that the componentsmay be located off-center, off-center and on-center at differentlocations, and that the core, the core and cladding and the core,cladding and coating may be longer or shorter than the one or more ofthe protective layers.

The core 1 is preferably composed of fused silica having a water contentof at most about 0.25 ppm or less. The core may be composed of othermaterials, such as those disclosed in US Patent Application PublicationNumbers 2010/0044106, 2010/0044105 and 2010/0215326 and in pending U.S.patent application Ser. No. 12/840,978, the entire disclosures of eachof which are incorporated herein by reference. Higher purity materials,and the highest purity material available, for use in the core arepreferred. Thus, this higher purity material minimizes the scatteringlosses caused by defects and inclusions. The core is about 200 to about700 microns in diameter, preferably from about 500 to about 600 micronsin diameter and more preferably about 600 microns in diameter.

The cladding 2 is preferably composed of fluorine doped fused silica.The cladding may be composed of other materials such as fused silicadoped with index-altering ions (germanium), as well as, those disclosedin US Patent Application Publication Numbers 2010/0044106, 2010/0044105and 2010/0215326 and in pending U.S. patent application Ser. No.12/840,978 the disclosures of each of which are incorporated herein byreference. The cladding thickness, depending upon the wavelength beingused and the core diameter, is from about 50 microns to about 250microns, preferably about 40 microns to about 70 microns and morepreferably about 60 microns. As used herein with respect to amulti-layer structure, the term “thickness” means the distance betweenthe layer's inner diameter and its outer diameter. The thickness of thecladding is dependent upon and relative to the core size and theintended wavelength. To determine the thickness of the cladding thefollowing may be considered the wavelength, dopant levels, NA, bendsensitivity, the composition and thickness of the outer coating oradditional claddings, and factors pertinent to end use considerations.Thus, by way of illustration in general fibers may fall within thefollowing for 1.1 micron wavelength the outer diameter of the claddingcould be 1.1× the outer diameter of core or greater; and, for a 1.5micron wavelength the outer diameter of the cladding could be 1.5× theouter diameter of the core or greater. Although a single cladding isillustrated, it is understood that multiple cladding may be utilized.

The coating 3 is preferably composed of a high temperature acrylatepolymer, for higher temperatures a polyimide coating is desirable. Thecoating may be composed of other materials, such a metal, as well asthose disclosed in US Patent Application Publication Numbers2010/0044106, 2010/0044105 and 2010/0215326 and in pending U.S. patentapplication Ser. No. 12/840,978 the disclosures of each of which areincorporated herein by reference. The coating thickness is preferablyfrom about 50 microns to about 250 microns, preferably about 40 micronsto about 150 microns and more preferably about 90 microns. The coatingthickness may even be thicker for extreme environments, conditions andspecial uses or it may be thinner for environments and uses that areless demanding. It can be tailored to protect against specificenvironmental and/or physical risks to the core and cladding that may beencountered and/or anticipated in a specific use for the cable.

The first protective layer 4 and the second protective layer 5 may bethe same or they may be different, or they may be a single compositelayer include different materials. Preferably the first and secondprotective layers are different materials.

The first protective layer may be thixotropic gel. This layer may beused to primarily protect the fiber from absorption loss from hydroxylions and vibration. Some gels set forth for example below, may bespecifically designed or used to absorb hydroxyl ions, or prevent themigration of substances to cause their formation. The thixotropic gelprotects the fiber from mechanical damage due to vibrations, as well as,provides support for the fiber when hanging vertically because itsviscosity increases when it is static. A palladium additive is be addedto the thixotropic gel to provide hydrogen scavenging. The hydrogenwhich diffuses into the fiber may be problematic for Germanium orsimilar ion doped cores. When using a pure fused silica core, it is lessof an effect and may be dramatically reduced. The first protective layermay be composed of other materials, such as, TEFLON, and those disclosedin US Patent Application Publication Numbers 2010/0044106, 2010/0044105and 2010/0215326 and in Pending U.S. patent application Ser. No.12/840,978 the disclosures of which are incorporated herein byreference. The thickness of the first protective layer should beselected based upon the environment and conditions of use as well as thedesired flexibility and/or stiffness of the cable and the design,dimensions and performance requirements for the conveyance structurethat they may be incorporated into or associated with. Thus, thecomposition and thickness of the first protective layer can be tailoredto protect against specific environmental and/or physical risks to thecore, cladding and coating that may be encountered and/or anticipated ina specific use for the cable. The use of the thixotropic gel providesthe dual benefit of adding in the manufacture of the cable as well asproviding mechanical protection to the core once the cable manufacturingis completed.

The second protective layer may be a stainless steel tube composed of316 stainless. The second protective layer may provide physical strengthto the fiber over great distances, as well as, protection from physicaldamage and the environment in which the cable may be used. The secondprotective layer may be composed of other materials, such as thosedisclosed US Patent Application Publication Numbers 2010/0044106,2010/0044105 and 2010/0215326 and in pending U.S. patent applicationSer. No. 12/840,978 the disclosures of each of which are incorporatedherein by reference. The second protective layer thickness may beselected based upon the requirements for use and the environment inwhich the cable will be used. The thickness my further be dependent uponthe weight and strength of the material from which it is made. Thus, thethickness and composition of the second protective layer can be tailoredto protect against specific environmental and/or physical risks to thecore, cladding and coating that may be encountered and/or anticipated ina specific use for the cable. The presence of, size, configuration andcomposition of the second protective layer may be based upon or tailoredto the design, dimensions, and performance requirements for theconveyance structure that the optical fiber cable may be incorporatedinto or associated with.

The need for, use of and configuration of the first, second, oradditional protective layers may be dependent upon the configurationdimensions and performance requirements for a conveyance structure thatthe optical fiber is associated with. One or more of these protectivelayers, if utilized, may be part of the conveyance structure, integralwith the conveyance structure, a separate or separable component of theconveyance structure, and combinations and variations of these.

The optical fiber cables, and the conveyance structures that they may beincorporated into or associated with, can be greater than about 0.5 km(kilometer), greater than about 1 km, greater than about 2 km, greaterthan about 3 km, greater than about 4 km and greater than about 5 km.These cables and structures can withstand temperatures of up to about300° C., pressures of up to about 3000 psi and as great as 36,000 psi,and corrosive environments over the length of the fiber withoutsubstantial loss of power and for extended periods of time. The opticalfiber cables and conveyance structures can have a power loss, for agiven wavelength, of less then about 2.0 dB/km, less than about 1.5dB/km, less then about 1.0 dB/km, less than about 0.5 dB/km and lessthan about 0.3 dB/km. The optical fiber cables and conveyance structurescan have power transmissions of at least about 50%, at least about 60%,at least about 80%, and at least about 90%.

The flexibility and/or stiffness of the optical fiber cable, conveyancestructure or both, can be varied based upon the size and types ofmaterials that are used in the various layers of the cable andstructure. Thus, depending upon the application a stiffer or moreflexible optical fiber cable, conveyance structure or both, may bedesirable. For some applications it is preferred that the optical fibercable, conveyance structure or both, have sufficient flexibility andstrength to be capable of being repeatedly wound and unwound from aspool or reel having an outside diameter of no more than about 6 m. Thisoutside diameter spool size can be transported by truck on publichighways. Thus, a spool or reel having an outside diameter of less thanabout 6 meters and comprising between 0.5 meters and 5 km of the opticalfiber cable or structure may be utilized. The spool or reel may have anoutside diameter of less than about 6 meters, less than about 3 meters,and less than about 2 meters, and comprising greater than about 0.5 km(kilometer), greater than about 1 km, greater than about 2 km, greaterthan about 3 km, greater than about 4 km and greater than about 5 km inlength of the optical fiber cable, conveyance structure or both.

An example of an embodiment of the optical fiber cable, that may be orbe part of a conveyance structure, would be a fused silica core of about600 microns diameter, a fluorine doped fused silica cladding, having athickness of 60 microns, a high temperature Acrylate coating having athickness of about 90 microns, a thixotropic gel or a TEFLON sleevefirst protective layer having a thickness of about 2500 microns, and a316 stainless steel second protective layer having an outer diameter ofabout 6250 microns and a length of about 2 km. The length of the fiberstructure includes the core, cladding and coating is longer than thelength of the stainless steel protective layer. This difference inlength addresses any differential stretch of the stainless steelrelative to the stretch of the fiber structure when the cable is in ahanging position, or under tensions, such as when it is extended down awell bore. The fiber has a numerical aperture of at least about 0.14.The fiber of this example can transmit a laser beam (wavelength 1080 nm)of about 20 kW (kilowatt) power, from the preferred laser, over adistance of about 2 km in temperatures of up to about 200° C. andpressures of about 3000 psi with less than 1 dB/km power loss.

Another example of an embodiment of an optical fiber cable, that may beor be part of a conveyance structure, would have a fused silica core ofabout 500 microns diameter, a fluorine doped fused silica cladding,having a thickness of 50 microns, an Acrylate coating having a thicknessof about 60 microns, and an ⅛ inch outer diameter stainless steelprotective layer and a length of about 2 km. The fiber has a numericalaperture (NA) of 0.22. The fiber of this example transmitted a laserbeam (wavelength 1080 nm) of about 10 kW (kilowatt) power, from thepreferred laser, over a distance of about 2 km in temperatures of up toabout 150 C.° and at ambient pressure and with less than 0.8 dB/km powerloss. This fiber was tested using an IPG YLR 20000 laser was operated aduty cycle of 10% for a 1 kHz pulse rate. The operating conditions wereestablished to keep the pulse duration longer than the time constant forSBS. Thus, the absence of SBS was the result of the fiber and laser, notthe pulse duration. The laser beam was transmitted through a 2 km fiber,evaluated in a test system along the lines of the test system shown inFIG. 3 of US Patent Publication Number 2010/0215326 and provided theresults set forth in Table 4, where peak power launched and power outputare in watts.

TABLE 4 Peak Power Peak Power Percentage Launched Output transmitted 924452 48.9 1535 864 56.3 1563 844 54.0 1660 864 52.0 1818 970 53.3 19321045 54.1 2000 1100 55.0 2224 1153 51.8 2297 1216 52.9 2495 1250 50.12632 1329 50.5 2756 1421 51.6 3028 1592 52.6 3421 1816 53.1 3684 198753.9 3947 2105 53.3 4342 2263 52.1 4605 2382 51.7 4868 2487 51.1

The spectrum for 4868 Watt power is shown at FIG. 2. The absence of SRSphenomenon is clearly shown in the spectrum. (As used herein terms suchas, “absence of”; “without any” or “free from” a particular phenomena oreffect means that for all practical purpose the phenomena or effect isnot present, and/or not observable by ordinary means used by one ofskill in the art) Further the linear relationship of the launch (input)and output power confirms the absence of SBS phenomena. Further, thepulsed operation of the laser may have caused the wavelength of thefiber laser to chirp, which may have further contributed to thesuppression of SBS and SRS phenomenon since this would result in aneffectively wider laser linewidth.

Turning to FIG. 3 there is provided a general configuration of anembodiment of a laser system. The arrangement of the components andstructures in this embodiment is by way of example, it being recognizedthat these components may be arrange differently on the truck chassis,or that different types of chassis and sizes may be used as well asdifferent components.

In particular, in the embodiment of FIG. 3. there is provided a mobilehigh power laser beam delivery system 300. In the embodiment there isshown a laser cabin or room 301. There is provided a source ofelectrical power 302, which may be a generator or electrical connectiondevice for connecting to a source of electricity. The laser room 301houses a laser source, which in this embodiment is a 20 kW laser havinga wavelength of about 1070-1080, (other laser sources, types,wavelengths, and powers may be utilized, and thus the laser source maybe a number of lasers, a single laser, or laser modules, collectivelyhaving at least about 5 kW, 10 kW, 20 kW, 30 kW 40 kW, 70 kW or morepower), which is preferably capable of being integrated with a controlsystem for an assembly to pay out and retrieve the conveyance structure,and any high power laser tool that may be used in conjunction with thesystem. Examples of high power laser tools are provided in U.S. PatentApplication Ser. No. 61/378,910, Ser. No. 61/374,594, and Ser. No.61/446,421, the entire disclosure of each of which is incorporatedherein by reference.

A high power fiber 304 leaves the laser room 301 and enters an opticalslip ring 303, thus optically associating the high power laser with theoptical slip ring. The fiber 304 may be by a commercially availableindustrial hardened fiber optic cabling with QBH connectors at each end.Within the optical slip ring the laser beam is transmitted from anon-rotating optical fiber to the rotating optical fiber that iscontained within the conveyance structure 306 that is wrapped aroundspool 305. The conveyance structure 306 is associated with cablehandling device 307, which may be a hydraulic boom crane or similar typedevice, that has an optical block 308. The optical cable block 308provides a radius of curvature when the optical cable is run over itsuch that bending and other losses are minimized. The distal end of theconveyance structure 306 has a connecting apparatus 309, which could bea fiber that is fused to a fiber in a tool or other laser equipment, afiber termination coupled to mechanical connecting means, a commerciallyavailable high power water cooled connecter, or more preferably aconnector of the type provided in U.S. Patent Application Ser. No.61/493,174, the entire disclosure of which is incorporated herein byreference.

The optical block may be an injector, a sheave, or any other freemoving, powered or similar device for permitting or assisting theconveyance structure to be paid out and retrieved. When determining thesize, e.g., radius of curvature, of the spool, the optical block orother conveyance structure handling devices care should be taken toavoid unnecessary bending losses, such as macro- and micro-bendinglosses, as well as, losses from stress and strain to the fiber, as forexample taught in U.S. patent application Ser. No. 12/840,978 the entiredisclosure of which is incorporated herein by reference. The conveyancestructure has a connector/coupler device 309, that is opticallyassociated with the optical fiber and that may be attached to, e.g.,optically or optically and mechanically associated with, a high powerlaser tool, another connector, an optical fiber or another conveyancestructure. The device 309 may also mechanically connect to the tool, aseparate mechanical connection device may be used, or a combinationmechanical-optical connection device may be used. Examples of suchconnectors are contained in U.S. Patent Application Ser. No. 61/493,174,the entire disclosure of which is incorporated herein by reference.

The conveyance structure 306 on spool 305 has at least one high poweroptical fiber, and may have additional fibers, as well as, otherconduits, cables, channels, etc., for providing and receiving material,data, instructions to and from the high power laser tool, monitoringconditions of the system and the tool and other uses. Although thissystem is shown as truck mounted, it is recognized the system could bemounded on, or in other mobile or moveable platforms, such as a skid, ashipping container, a boat, a barge, a rail car, a drilling rig, a workover rig, a work over truck, a drill ship, a fixed platform, or it couldbe permanently installed at a location.

The spool may have a conveyance structure wound around the spool, theconveyance structure being capable of being unwound from and wound ontothe spool, and thus being rewindable. The conveyance structure having alength greater than about 0.5 km, about 1 km, about 2 km, about 3 km andgreater and may have: a core; a cladding; a coating; a first protectivelayer; and, a second protective layer. The conveyance structure may becapable of transmitting high power laser energy for its length with apower loss of less than about 2 dB/km and more preferably less thanabout 1 dB/km and still more preferably less than about 0.5 dB/km andyet more preferably about 0.3 dB/km. The outer diameter of the spoolwhen wound is preferably less than about 6 m (meters) to facilitatetransporting of the spool by truck.

The conveyance structure handling apparatus may be a part of, associatedwith, independent from, or function as an optical block. The handlingapparatus may be, for example, a spool. There are many varied ways andconfigurations to use a spool as a handling apparatus; although, theseconfigurations may be generally categorized into two basic spoolapproaches.

The first approach is to use a spool, which is simply a wheel withconveyance structure coiled around the outside of the wheel. Forexample, this coiled conveyance structure may be a hollow tube, acomposite tube, a complex walled tube, it may be an optical fiber, itmay be a bundle of optical fibers, it may be an armored optical fiber,it may be other types of optically transmitting cables or it may be ahollow tube that contains the aforementioned optically transmittingcables.

In this first general type of spool approach, the spool in thisconfiguration has a hollow central axis, or such an axis is associatedwith the spool, where the optical power is transmitted to the input endof the optical fiber. The beam will be launched down the center of thespool, the spool rides on precision bearings in either a horizontal orvertical orientation to prevent any tilt of the spool as the fiber isspooled out. It is optimal for the axis of the spool to maintain anangular tolerance of about +/−10 micro-radians, which is preferablyobtained by having the optical axis isolated and/or independent from thespool axis of rotation. The beam when launched into the fiber islaunched by a lens which is rotating with the fiber at the FourierTransform plane of the launch lens, which is insensitive to movement inthe position of the lens with respect the laser beam, but sensitive tothe tilt of the incoming laser beam. The beam, which is launched in thefiber, is launched by a lens that is stationary with respect to thefiber at the Fourier Transform plane of the launch lens, which isinsensitive to movement of the fiber with respect to the launch lens.

The second general type of spool approach is to use a stationary spoolsimilar to a creel and rotate the distal end of the structure or thelaser tool attached to the distal end of the fiber in the structure, asthe conveyance structure spools out to keep the conveyance structure andthus the fiber from twisting as it is extracted from the spool. If thefiber can be designed to accept a reasonable amount of twist along itslength, then this may be the preferred method. Using this type of thesecond approach if the conveyance structure, and thus, the fiber couldbe pre-twisted around the spool then as the conveyance structure and thefiber are extracted from the spool, the conveyance structure straightensout and there is no need for the fiber and in particular its distal endto be rotated as the conveyance structure is paid out. There may be aseries of tensioners that can suspend the fiber down the hole, or if thehole is filled with water to extract the debris from the bottom of thehole, then the fiber can be encased in a buoyant casing that willsupport the weight of the fiber and its casing the entire length of thehole. In the situation where the distal end does not rotate and thefiber is twisted and placed under twisting strain, there will be thefurther benefit of reducing SBS as taught herein.

The handling apparatus may have QBH fibers and a collimator. Vibrationisolation means are also desirable in the construction of the handlingapparatus, and in particular for a fiber slip ring. Thus, using theexample of a spool, the spool's outer plate may be mounted to the spoolsupport using a Delrin plate, while the inner plate floats on the spooland pins rotate the assembly. The fiber slip ring is the stationaryfiber, which communicates power across the rotating spool hub to therotating fiber.

When using a spool the mechanical axis of the spool is used to transmitoptical power from the input end of the optical fiber to the distal end.This calls for a precision optical bearing system (the fiber slip ring)to maintain a stable alignment between the external fiber providing theoptical power and the optical fiber mounted on the spool. The laser canbe mounted inside of the spool, or other handling apparatus, or on adevice that rotates the laser as the spool or other handling apparatusis rotated. As shown for example in FIG. 13 the laser can be mountedexternal to the spool or if multiple lasers are employed both internaland external laser locations may be used. The internally, e.g.,rotationally, mounted laser may, for example, be a high power laser forproviding the high power laser beam for the remote laser activities, itmay be a probe or monitoring laser, used for analysis and monitoring ofthe system and methods performed by the system or it may be both.Further, sensing and monitoring equipment may be located inside of, orotherwise affixed to, the rotating elements of the spool, or otherhandling apparatus.

There is further provided a rotating coupler, that may be used with somehandling apparatus, to connect the conveyance structure, which isrotating, to the laser beam transmission fiber and any fluid orelectrical conveyance conduits, which are not rotating. As illustratedby way of example in FIG. 8, a spool of coiled tubing 809 has tworotating coupling means 813. One of said coupling means has an Opticalrotating coupling means 802 and the other has a fluid rotating couplingmeans 803. The optical rotating coupling means 802 can be in the samestructure as the fluid rotating coupling means 803 or they can beseparate. Thus, preferably, two separate coupling means are employed.Additional rotating coupling means may also be added to handle othercables, such as for example cables for downhole probes.

The optical rotating coupling means 802 is connected to a hollowprecision ground axle 804 with bearing surfaces 805, 806. The lasertransmission means 808 is optically coupled to the hollow axle 804 byoptical rotating coupling means 802, which permits the laser beam to betransmitted from the laser transmission means 808 into the hollow axle804. The optical rotating coupling means for example may be made up of aQBH connector, a precision collimator, and a rotation stage, for examplea Precitec collimator through a Newport rotation stage to anotherPrecitec collimator and to a QBH collimator. To the extent thatexcessive heat builds up in the optical rotating coupling cooling shouldbe applied to maintain the temperature at a desired level.

The hollow axle 804 then transmits the laser beam to an opening 807 inthe hollow axle 804, which opening contains an optical coupler 810 thatoptically connects the hollow axle 804 to the long distance high powerlaser beam transmission means 825 that may be located inside of a tubing812. Thus, in this way the laser transmission means 808, the hollow axle804 and the long distance high power laser beam transmission means 825are rotatably optically connected, so that the laser beam can betransmitted from the laser to the long distance high power laser beamtransmission means 825.

A further illustration of an optical connection for a rotation spool isprovided in FIG. 6, wherein there is illustrated a spool 600 and asupport 601 for the spool 600. The spool 600 is rotatably mounted to thesupport 601 by load bearing bearings 602. An input optical cable 603,which transmits a laser beam from a laser source (not shown in thisfigure) to an optical coupler 605. The laser beam exits the connector605 and passes through optics 609 and 610 into optical coupler 606,which is optically connected to an output optical cable 604. The opticalcoupler 605 is mounted to the spool by a preferably non-load bearing 608(e.g., the bearing 608 is not carrying, or is isolated or at leastpartially isolated from, the weight of the spool assembly), whilecoupler 606 is mounted to the spool by device 607 in a manner thatprovides for its rotation with the spool. In this way as the spool isrotated, the weight of the spool and coiled tubing is supported by theload bearing bearings 602, while the rotatable optical coupling assemblyallows the laser beam to be transmitted from cable 603 which does notrotate to cable 604 which rotates with the spool.

In addition to using a rotating spool of tubing, another device to payout and retrieve, or for extending and retrieving, the conveyancestructure is a stationary spool or creel. As illustrated, by way ofexample, in FIGS. 9A and 9B there is provided a creel 909 that isstationary and which contains coiled within the long distance high powerlaser beam transmission means 925. That means is connected to the laserbeam transmission conveyance structure 908, which is connected to thelaser (not shown in this figure). In this way the laser beam may betransmitted into the long distance high power laser beam transmissionfiber associated with, or being, the conveyance structure and thatstructure may be deployed down a borehole, or to a remote location wherethe high power laser energy may be utilized, by for example a high powerlaser tool. The long distance high power laser beam transmissionconveyance structure may be for example, a coiled tubing, linestructure, or composite tube, on the creel. The optical fiber associatedtherewith may preferably be an armored optical fiber of the typeprovided herein. In using the creel consideration should be given to thefact that the conveyance structure and thus the optical fiber will betwisted when it is deployed. To address this consideration the distalend of the fiber, the conveyance structure, the bottom hole assembly, orthe laser tool, may be slowly rotated to keep the optical cableuntwisted, the conveyance structure may be pre-twisted, the conveyancestructure and optical fiber may be designed to tolerate the twisting andcombinations and variations of these.

In FIG. 10 there is provided a conveyance structure handling apparatus1000 having a housing 1020 and an opening 1021. Apparatus 1000 has anassembly 1021 for winding and unwinding the high power conveyancestructure 1010. The assembly 1021 has roller 1022, 1023. In thisembodiment the structure is stored in a helix 1025 that can be unwoundand rewound as the tool is deployed and recovered. The distal end of theconveyance structure has a connecting apparatus 1030, which could be afiber that is fused to a fiber in a tool or other laser equipment, afiber termination coupled to mechanical connecting means, a commerciallyavailable high power water cooled connecter, or more preferably aconnector of the type provided in U.S. Patent Application Ser. No.61/493,174, the entire disclosure of which is incorporated herein byreference. The proximal end 1040 may be optically associated with a highpower laser source.

This type of device could be mounted with the laser as a modular system,an integrated system, a unified mobile system, or separate from andoptically associable with a high power laser or laser cabin.

The embodiment of FIG. 10, and the embodiment of FIG. 9, do not requirean optical slip ring in order to have the high power laser maintained inoptical association with the conveyance structure as it is paid andretrieved. In the handling apparatus configurations, such as therotating spool, in general, an optical slip ring is used, as describedabove, to enable the laser to be maintained in optical association withthe conveyance structure, and the structures distal end and laser tool,while the conveyance structure is being paid out and retrieved. It beingunderstood that in such rotating spool type structures, the optical slipring may not be used, in which case the conveyance structure would bewound out to a desired length, or depth, and then the high power laserwould be optically connected to its proximal end, e.g., the endremaining on the spool. Preferably the unwound length of conveyancestructure would be slightly greater than, or greater than the depth, ordistance to the work site location, so that sufficient extra unwoundconveyance structure would be present to move the laser tool in anymanner needed to perform an intended laser operation, such as forexample, up and down within the borehole to cut a window.

In FIG. 11 there is provided an embodiment of a handling apparatus thatis configured to provide figure-8 looped wraps. This configuration doesnot require an optical slip ring and does not place twist in theconveyance structure. Thus, in FIG. 11 there is provided a Figure-8looping apparatus 1112 having a base 1101. The base has two wrappingposts 1105, 1106. The conveyance structure 1102 has a proximal end 1103,which may be connected to a high power laser or laser cabin, and adistal end 1104, which is paid out and may be associated with a lasertool. As shown in FIG. 11, the conveyance structure is formed intoseveral figure-8 loops, one located above the next. Thus, for purpose ofillustration, four such loops are shown: a first loop 1107 which islowest and adjacent the base 1101; a second loop 1108, which isgenerally above the first loop 1107, a third loop 1109, which isgenerally above the second loop 1108, and a fourth loop 1110, which isgenerally above the third loop 1109. Although four loops are shown, itis understood that for a conveyance structure a km or longer, many more,hundreds and potentially thousands, of such figure-8 loops will bepresent.

In FIGS. 12A, 12B, and 12C there is provided an embodiment of a handlingapparatus. In this embodiment a reverse wrap conveying structure isutilized. Thus, there is a reverse wrap conveying structure 1200 havinga first preformed helical section 1201, a second helical section 1202,which is an opposite helix from the first. These sections are connectedby a flip back hinge like section 1203. Several passages may becontained within this structure, for example a high pressure air conduit1205, a high power laser fiber 1206, an electrical cable 1207, and amonitoring laser fiber 1208. The hardware and outer components for thistype of reverse wrap conveying structure may be obtained from Igus,under the trade name TWISTERBAND. This type of reverse wrap conveyingstructure is an example of a conveying structure that can also functionas a handling apparatus.

By way of example, the conveyance structures whether or not associatedwith handling apparatus can range in lengths from: 1 km (3,280 ft) to 9km (29,528 ft); from 2 km (6,561 ft) to 5 km (16,404 ft); at least about5 km (16,404 ft); and from about 5 km (16,404 ft) to at least about 9 km(29,528 ft).

In FIG. 13 there is provided a schematic drawing of an embodiment of alaser system 1312, having a laser room or cabin 1300 and a spool 1301.In this embodiment the laser room 1300 contains a high power beam switch1302, a high power laser unit 1303 (which could be a number of lasers, asingle laser, or laser modules, collectively having at least about 5 kW,10 kW, 20 kW, 30 kW 40 kW, 70 kW or more power), a chiller assembly 1304for the laser unit 1303 and a control console 1305 that preferably is incontrol communication with a control system and network 1310.Additionally multiple laser may be combined with a high power beamcombiner to launch about 40 kW, about 60 kW about 80 kW or greater downa single fiber. Although shown has having all of the components of thechiller in the room (in which case the air inflows and outflows wouldhave to vented to the outside, which venting is not shown in thisschematic), the larger components of the chiller 1304, such as the heatexchanger components, may be located outside of the laser room 1300,both for space, noise and heat management purposes. The high power laserunit 1303 is optically connected to the beam switch 1302 by high poweroptical fiber 1306. The beam switch 1302 optically connects to spool1301 by means of an optical slip ring 1308, which in turn optically androtationally connects to the conveyance structure 1309. In higher powersystems, e.g., greater than 20 kW the use of multiple fibers, multiplebeam switches, and other multiple component type systems may beemployed. These may, among other things provide greater safety andreliability to such higher power systems. The conveyance structure isthen capable of being attached to a high power laser tool or other highpower laser device. The distal end of the conveyance structure 1309 hasa connecting apparatus 1340, which could be a fiber that is fused to afiber in a tool or other laser equipment, a fiber termination coupled tomechanical connecting means, a commercially available high power watercooled connecter, or more preferably a connector of the type provided inU.S. Patent Application Ser. No. 61/493,174, the entire disclosure ofwhich is incorporated herein by reference.

A second conveyance structure 1311, which could also be an opticalfiber, leaves the beam switch 1302. This second conveyance structure1311 could be used with a different spool for use with a different tool,directly connect to a tool, or connected to a separate high power laserlab, tool testing, or work area (not shown in this figure). Electricalpower can be supplied from the location where the laser room is located,from the mobile unit that transported the laser room, from separategenerators, separate mobile generators, or other sources of electricityat the work site or bought to the work site.

Preferably in a high power laser system a controller is incommunication, via a network, cables fiber or other type of factory,marine or industrial data and control signal communication medium withthe laser tool and potentially other systems at a work site. Thecontroller may also be in communication with a first spool of high powerlaser cable, a second spool of high power laser cable and a third spoolof high power laser cable, etc. Examples of control systems and networksfor high power laser systems are provided in U.S. Patent ApplicationSer. No. 61/446,412 the entire disclosure of which is incorporatedherein by reference.

It should be noted that the configuration, placement, number, andspecific types of equipment in a high power laser system, a mobile laserstructure, a laser cabin, or a handling apparatus are not limited to theexemplary embodiments that are provided herein and are not limited tothe illustrations in the figures provided herein. Thus, it is envisionedand contemplated by this specification that different and variedcombinations, arrangements, placements, numbers, and types of equipmentmay be utilized without departing from the spirit and teaching of thisspecification.

The following Examples 1 to 13 and 22 to 23, provide embodiments ofconveyance structures. Other composite tube structures, such as thosedisclosed in U.S. Pat. No. 7,647,948, the entire disclosure of which isincorporated herein by reference, may have high power long distancelaser fibers associated with them and thus be a conveyance structure. Itshould be noted that the configuration, placement, number, and specifictypes of components of conveyance structures are not limited to theexemplary embodiments that are provided in Examples 1 to 13, and 22 to23. Thus, it is envisioned and contemplated by this specification thatdifferent and varied combinations, arrangements, placements, numbers,and types of components may be utilized in a conveyance structurewithout departing from the spirit and teaching of this specification.Additionally, these conveyance structures may be used with different andvaried types of handling apparatus, mobile laser systems and opticalblocks.

Conveyance structures and their components may be made from varies typesof material including metals, plastics and composites. The materials ofconstruction should be selected to meet particular intended userequirements and may take into consideration factors such as pressure(internal and external), flow rates, temperatures, corrosiveenvironments, stress and strain. Thus, they may be for example: a metaltube; a braided tube; a composite material and combinations andvariations of these. They may be made from metals such as for example:steel; stainless steel; aluminum; titanium; phosphor bronze; copper;bronze; inconel; and monel. They may be made for example from compositessuch as: carbon fiber; fiberglass; Kevlar; Aramid; Boron fibers; metalmatrix composites; cermet (ceramic metal); nanocomposites; matrix-resinsolutions (e.g., polyester (isophthalic and orthophthalic); vinyl ester;epoxy; phenolic; polyimide; cyanate-ester-based; and acrylate-based.They may be made from polymers, such as: Acetal polymers (e.g., deirin;acetal copolymer; or turcite); PEEK including filled versions;Polyamide-imide (Torlon); Polystyrene; polycarbonate; Polypropylene; PPS(e.g., Techtron; Fortron; Ryton); Polyethene (e.g., LDPE; HDPE; UHMW;VHMW); Polyester (e.g., PET; PETG; Hydex); PVC; Radel; Acrylic; ABS;Garolite; Nylon; fluoropolymers (e.g., TEFLON; FEP; ETFE; CTFE; ECTFE(Halar); Rulon; PTFE; PFA; PVDF (Kynar); and FEP). They may be made fromor use materials such as: fiberglass; fiberglass reinforced in epoxyresin matrix; carbon fiber; electrical grade glass; Kevlar (aramidfiber); epoxy resins; fiberglass reinforced thermoset polyester;polyester; vinyl ester; plastic; glass reinforced plastic; high densitypolyethylene; fluoroplastic; thermalplastic,s as well as othermaterials, compositions and structures that that may be used for suchmembers, or are otherwise known to, or later developed by, those ofskill in the art.

The conveyance structures of Examples 1 to 13, and 22 to 23 may begreater than 0.5 km, greater than 1 km, greater than 2 km, greater than3 km, and greater than 5 km in length. By way of example, thesestructure may use a high power optical fiber having. Pull from connectorapplication.

Example 1

An embodiment of a conveyance structure is provided in FIG. 14. Awireline conveyance structure 1450 having two layers of helically woundarmor wires, an outer layer 1451 and an inner layer 1452 are present.The conveyance structure 1450 has a plurality of insulated electricalconductors 1453 and a high power optical fiber capable of reducingnon-linear effects 1454, which has an optical fiber 1455 and an outerprotective member 1456. The space 1458 between the outer surface of thefiber and the inner surface of the protective member, may further befilled with, or otherwise contain, a gel, protective sleeve, anelastomer or some other material, such as a liquid (provided the liquiddoes not damage the fiber, e.g., through for example hydrogen migrationor solvent effects). Similarly, a second space 1459 may further befilled with, or otherwise contain, a gel, an elastomer or some othermaterial, such as a fluid, which material will prevent the armor wiresfrom crushing inwardly from external pressure of an application, such asthe pressure found in a well bore. Further the fiber may be packaged ina TEFLON sleeve or equivalent type of material or sleeve.

Example 2

An embodiment of a conveyance structure is provided in FIG. 15, whichillustrates a wireline type conveyance structure 1560 having outer armorwire layer 1561 and inner armor wire layer 1562. The conveyancestructure 1560 has a high power optical fiber 1565 and an outerprotective member 1566. The space 1569 between the optical fiber 1565and the outer protective member 1566 may further be filled with, orotherwise contain, a gel, a protective sleeve, an elastomer or someother material, such as a liquid (provided the liquid does not damagethe fiber, e.g., through for example hydrogen migration or solventeffects), which material will prevent the armor wires from crushinginwardly from external pressure of an application, such as the pressurefound in a well bore. Further the fiber may be packaged in a TEFLONsleeve or equivalent type of material or sleeve.

Example 3

An embodiment of a conveyance structure is provided in FIG. 16. Thisembodiment has a conveyance structure 1606, having an inner member 1621,e.g., a tube, the inner member 1621 having an open area or open space1622 forming a channel, passage or flow path. The conveyance structure1606 has a plurality of lines 1623, e.g., electric conductors, hydrauliclines, tubes, data lines, fiber optics, fiber optics data lines, highpower optical fibers capable of suppressing or managing non-lineareffects, and/or high power optical fibers in a metal tube, TEFLONsleeve, or other protective layer. The conveyance structure 1606 has anouter member 1625. The inner member 1621 and the outer member 1625 maybe made from the same material and composition, or they may be differentmaterials and compositions. The area between the outer member 1625 andthe inner member 1621 is filled with and/or contains a supporting orfilling medium 1624, e.g., an elastomer or the same or similar materialthat the inner member and/or outer member is made from. In theconfiguration of this embodiment the lines are positioned such that theyare outward of and surround the inner member.

Example 4

An embodiment of a conveyance structure is provided in FIG. 17. Theconveyance structure 1706 has two inner members, 1731 a and 1731 b,e.g., tubes. The inner members 1731 a and 1731 b forms an open area, orchannel, or flow path 1732 a, 1732 b. The conveyance structure 1706 hasa plurality of lines 1733, e.g., electric conductors, hydraulic lines,tubes, data lines, fiber optics, fiber optics data lines, high poweroptical fibers capable of suppressing or managing non-linear effects,high power optical fibers, and/or high power optical fibers in a metaltube, TEFLON sleeve, or other protective layer. The structure 1706 hasan outer member 1735. The area between the outer member 1735 and theinner members 1731 a and 1731 b is filled with and/or contains asupporting medium 1734, e.g., an elastomer or the same or similarmaterial that the inner member and/or outer member is made from. In theconfiguration of this embodiment the lines are positioned such that theyare outward of and surround the inner members.

Example 5

An embodiment of a conveyance structure is provided in FIG. 18. Theconveyance structure 1806, has inner members, 1841 a and 1841 b, e.g., atubes, the inner members 1841 a and 1841 b having an open area or openspace 1842 a, 1842 b associated therewith, which space forms a channel,passage or flow path. The conveyance structure 1806 has a plurality oflines 1843, e.g., electric conductors, hydraulic lines, tubes, datalines, fiber optics, fiber optics data lines, high power optical fiberscapable of suppressing or managing non-linear effects, high poweroptical fibers, and/or high power optical fibers in a metal tube, TEFLONsleeve, or other protective layer. The conveyance structure 1806 has anouter member 1845. The area between the outer member 1845 and the innermembers 1841 a and 1841 b is filled with and/or contains a supportingmedium 1844, e.g., an elastomer or the same or similar material that theinner member and/or outer member is made from. The inner members and theouter member may be made of the same or different materials, includingthe materials listed in Example 3. In the configuration of thisembodiment the lines are positioned such that they are between the innermembers.

Example 6

An embodiment of a conveyance structure is provided in FIG. 19. Theconveyance structure 1906 has an inner member 1951, e.g., a tube. Theinner member 1951 has an open area or open space 1952, which space formsa channel, cavity, flow path, or passage. The conveyance structure 1906has a plurality of lines 1953, e.g., electric conductors, hydrauliclines, tubes, data lines, fiber optics, fiber optics data lines, highpower optical fibers capable of suppressing or managing non-lineareffects, high power optical fibers, and/or high power optical fibers ina metal tube, TEFLON sleeve, or other protective layer. The conveyancestructure 1906 has an outer member 1955. The area between the outermember 1955 and the inner member 1951 is filled with and/or contains asupporting medium 1954, e.g., an elastomer or the same or similarmaterial that the inner member and/or outer member is made from. In theconfiguration of this embodiment the lines are positioned such that theyare directly adjacent the inner and outer members.

Example 7

An embodiment of a high power conveyance structure is provided in FIGS.20A and 20B. There is shown a cross section and side view (FIG. 20B) ofa composite conveyance structure. In FIG. 20A there is provided across-section of a composite conveyance structure 2000. There is anextruded inner member 2002, having an open space 2001, which forms achannel, passage, or flow path. Around the extruded core, preferably ina spiral fashion, lines 2003 and 2004 are positioned around and alongthe extruded inner member 2002. Line 2003 is a high power laser fiberhaving a core diameter of 1,000 microns, a dual clad and a TEFLONprotective sleeve and Line 2004 is an electrical power cable. A highdensity polymer 2005 then coats and encapsulates the lines 2003, 2004and the extruded inner member 2002. The high density polymer 2005 formsan outer surface 2006 of the composite tube 2000. FIG. 20B shows asection of the conveyance structure 2000, with the lines 2003, 2004wrapped around the extruded tube 2002. The high density polymer 2005 andouter surface 2006 are shown as phantom lines, so that the spiralarrangement of lines 2003, 2004 can be seen.

Example 8

An embodiment of a carbon composite conveyance structure is provided inFIG. 21. The carbon composite conveyance structure 2101 has a body 2102that has an inner side 2104, and an outer side 2103. The body forms aninner opening 2105, which provides a flow path for drilling or cuttingmedia, such as mud, nitrogen, or air. Contained within the body 2102 aredata and/or control lines 2106, 2107, and 2018. These lines may bewires, optical fibers or both for transmitting and receiving controlsignals and operating data. A high power optical fiber 2010, containedwithin a 0.125″ stainless steel tubing 2019 is contained within the body2102. Clean gas, air, nitrogen or a liquid (provided the liquid does notdamage the fiber, e.g., through for example hydrogen migration orsolvent effects; if the fluid is present in the laser beam path thefluid should also be selected to be highly transmissive to thewavelength of the laser beam being utilized) may be flowed down theannulus between the inner surface of the stainless tube 2110 and theouter surface of the optical fiber 2110. This flow may be used to cool,pressurize, or clean downhole high power optics. If the flow is acrossthe laser beam path the flow material should be selected to minimize thematerials absorbance of the laser beam. Large gauge electrical powerwires 2111, 2112 are contained within the body 2102 and may be used toprovide electrical power to a tool, cutting tool, drilling tool,tractor, or other downhole or remote piece of equipment.

Example 9

An embodiment of a conveyance structure is provided in FIG. 22. Theconveyance structure 2201 has a body 2202 that has an inner side 2204,and an outer side 2203. The body forms an inner opening 2205 and a firstear or tab section 2213 and a second ear or tab section 2214. The bodyis solid and may be made from any of the materials discussed above thatmeet the intended use or environmental requirements for the structure.The opening 2205, is formed by an inner member 2220, which may be acomposite tube, and provides a flow path for drilling or cutting media,such as mud, nitrogen, or air. Contained within tab 2213 of body 2202are data and/or control lines 2206, 2207, and 2218. These lines may bewires, optical fibers or both for transmitting and receiving controlsignals and operating data. A high power optical fiber 2210, containedwithin a 0.125″ stainless steel tubing 2219 is contained within tab 2214of body 2202. Clean gas, air, nitrogen or a liquid (provided the liquiddoes not damage the fiber, e.g., through for example hydrogen migrationor solvent effects; if the fluid is present in the laser beam path thefluid should also be selected to be highly transmissive to thewavelength of the laser beam being utilized) may be flowed down opening2218 that is formed by the inside 2217 of 0.50 stainless steel tubing2215. The tubing 2215 has an outer side 2216, which is in contact withthe body 2214. This flow may be used to cool, pressurize, or cleandownhole high power optics and/or it may be used to form a jet to assistin laser cutting or drilling. If the flow is across the laser beam paththe flow material should be selected to minimize the materialsabsorbance of the laser beam. Large gauge electrical power wires 2211,2212 are contained within tab 2213 of the body 2202 and may be used toprovide electrical power to a tool, cutting tool, drilling tool,tractor, or other down hole or remote piece of equipment.

In embodiments, such as that of Example 9, the use of a plastic orpolymer to form the inner surface of the passage conveying the clean gasflow, provide the ability to have very clean gas, which has advantageswhen the clean gas is in contact with optics, the laser beam path orboth.

Example 10

An embodiment of a conveyance structure is provided in FIG. 23. Theconveyance structure 2301 has a steel coiled tubing 2302 which forms apassage, flow path or channel 2310. Contained within channel 2310 is acomposite pipe 2303, which forms a passage, flow path or channel 2309.Channel 2310 may be used to transmit drilling or cutting material suchas mud, air or nitrogen. Channel 2309 contains a ⅛″ stainless steel tube2304 holding a high power laser optical fiber 2311. Also containedwithin channel 2309 are data lines 2308, 2307 and electrical power lines2305, 2306. Channel 2309 may be used to convey clean fluids, gasses orliquids, that may be used with or in conjunction with the downholeoptics and laser beam paths. Depending upon the intended flow path andthe intended association with or interaction with the laser beam path,the fluid should preferably be transmissive, and more preferably highlytransmissive to the wavelength of the laser beam intended to betransmitted by fiber 2311. In this embodiment as the coiled steel tubing2302 is worn out, damaged or fatigued, the composite pipe 2303 can beremoved, placed in a new coiled steel tubing, and reused.

Example 11

An embodiment of a conveyance structure is provided in FIG. 24. Theconveyance structure 2401 has an outside diameter 2404 that is about0.6836″. The conveyance structure 2401 has an outer armor layer having38 wires 2402 that are spiral wound and have a diameter of 0.0495″ andhas an inner armor layer having 42 wires 2403 that are spiral wound andhave a diameter of 0.0390″. Inside of the inner armor are seven 20 AWGconductor wires 2405 and two 0.0625″ stainless steel tubes with highpower optical fibers 2406. The conveyance structure 2401 has an innerstainless steel tube 2407 having an inner side 2408 and an outer side2409. The outer side 2409 is adjacent the conductor wires 2405 and thetubes-with-fibers 2406. The area 2411 between the outer side 2409 andthe inner armor layer may be filled with an elastomer or a polymer orother similar type of material such as a high density polymericmaterial. The stainless steel tube 2407 has an outer diameter of 0.375″and its inner side 2408 forms a space 2401 that creates a channel,passage or flow path. polypropylene a resin, such as protective wires

Example 12

An embodiment of a conveyance structure is provided in FIG. 25. Theconveyance structure 2501 has an outside diameter 2502 that is about1.0254″. The conveyance structure 2501 has an outer armor layer having38 wires 2503 that are spiral wound and have a diameter of 0.0743″ andhas an inner armor layer having 42 wires 2504 that are spiral wound andhave a diameter of 0.0585″. Inside of the inner armor are eight 20 AWGconductor wires 2507 and two 0.25″ stainless steel tubes with high poweroptical fibers 2505. The conveyance structure 2501 has two innerstainless steel tubes 2506 a and 2506 b each having an outer diameter of0.375″. The tubes may be used to carry the same or different fluids ormaterials. In one application the tubes may be used to carry liquidsand/or gasses having different indices of refraction, for example tube2506 a may carry water and tube 2506 b may carry an oil. The area 2512inside of the inner armor layer may be filled with an elastomer or apolymer or other similar type of material such as a high densitypolymeric material.

Example 13

An embodiment of a conveyance structure is provided in FIG. 26. Theconveyance structure 2601 has an outside diameter 2602 that is about1.0254″. The conveyance structure 2601 has an outer armor layer having38 wires 2603 that are spiral wound and have a diameter of 0.0743″ andhas an inner armor layer having 42 wires 2604 that are spiral wound andhave a diameter of 0.0585″. Inside of the inner armor are eight 20 AWGconductor wires 2607 and one 0.25″ stainless steel tubes with high poweroptical fibers 2605. The conveyance structure 2601 has two innerstainless steel tubes 2606 a and 2606 b each having an outer diameter of0.375″. The tubes may be used to carry the same or different fluids ormaterials. In one application the tubes may be used to carry liquidsand/or gasses having different indices of refraction, for example tube2606 a may carry water and tube 2606 b may carry an oil. The area 2612inside of the inner armor layer may be filled with an elastomer or apolymer or other similar type of material such as a high densitypolymeric material.

Although steel coiled tubing and composite tubing, and combinations ofthese are contemplated by this specification, composite tubing for usein a conveyance structure may have some advantages in that its use canreduce the size of the rig needed, can reduce the size of the injectoror handling apparatus and optical block needed and may also reduce theoverall power consumption, e.g., diesel fuel, that is used by theequipment. The inner channels of composite tubing also provide greatercontrol over the cleanliness, and thus, in situations where the channelis in fluid communication with high power laser optics or high powerlaser beam paths this feature may prove desirable. The compositematerials as seen in the above examples have the ability to imbed manydifferent types of structures and components within them, and may bedesigned to have a memory that either returns the structure to straightfor easy of insertion into a borehole, or to a particular curvature, foreasy of winding. Composite conveyance structures may be idea for usewith laser cutting tools for workover applications such as cutting andmilling and for use with electric motor laser bottom hole assemblyboring apparatus. These composite structures provide the ability to havemany varied arrangement of components, such as by way of example: asingle line (fiber or electric) packaged in a protective member; asingle power transmission optical fiber packaged in a protective member;multiple fibers or lines individually packages and wound inside of acomposite tube; multiple fiber ribbons (e.g., multiple fibers packagedinto a ribbon which is then wound inside of a composite tube); fiberbundles in individual metal tubes which are bundled helically and thenwould within the composite tube; clean gas purge lines, which are linesto transport nitrogen, or other purge gas material to the laser tools orlaser equipment and which would be wound inside of the composite tube;preselected index matching fluid lines to transport optically propertiedfluid to the laser tools or laser equipment and which would be wouldinside of the composite tube.

In some embodiments the conveyance structures may be very light. Forexample an optical fiber with a Teflon shield may weigh about ⅔ lb per1000 ft, an optical fiber in a metal tube may weight about 2 lbs per1000 ft, and other similar, yet more robust configurations may way aslittle as about 5 lbs per 1000 ft or less, about 10 lbs per 1000 ft, orless, and about 100 lbs per thousand feet or less. Should weight not bea factor and for very harsh and/or demanding uses the conveyancestructures could weight substantially more.

The following Examples 14 to 22 provide embodiments of high power lasersystems having conveyance structures and handling apparatus. It shouldbe noted that the configuration, placement, number, and specific typesof components, including the high power laser(s), conveyance structuresand handling apparatus are not limited to the exemplary embodiments thatare provided in Examples 14 to 22. The conveyance structures of Examples1 to 13 and 23 to 24, may be used with, or as a part of, the lasersystems of Examples 12 to 22. Thus, it is envisioned and contemplated bythis specification that different and varied combinations, arrangements,placements, numbers, and types of components may be utilized in highpower mobile laser systems without departing from the spirit andteachings of this specification.

Example 14

An embodiment of a high power laser system and its deployment in thefield are provided in FIGS. 27A to 27D. Thus, there is provided a mobilelaser conveyance truck (MLCT) 2700. The MLCT 2700 has a laser cabin 2701and a handling apparatus cabin 2703, which is adjacent the laser cabin.The laser cabin 2701 and the handling cabin 2703 are located on a truckchassis 2704. The MLCT 2700 has associated with it a lubricator 2705,for pressure management upon entry into a well.

The laser cabin 2701 houses a high power fiber laser 2702, (20 kW;wavelength of 1070-1080 nm); a chiller assembly 2706, which has an airmanagement system 2707 to vent air to the outside of the laser cabin andto bring fresh air in (not shown in the drawing) to the chiller 2706.The laser cabin also has two holding tanks 2708, 2709. These tanks areused to hold fluids needed for the operation of the laser and thechiller during down time and transit. The tanks have heating units tocontrol the temperature of the tank and in particular to prevent thecontents from freezing, if power or the heating and cooling system forthe laser cabin was not operating. A control system 2710 for the laserand related components is provided in the laser cabin 2703. A partition2711 separates the interior of the laser cabin from the operator booth2712.

The operator booth contains a control panel and control system 2713 foroperating the laser, the handling apparatus, and other components of thesystem. The operator booth 2712 is separated from the handling apparatuscabin 2703 by partition 2714.

The handling apparatus cabin 2703 contains a spool 2715 (about 6 ft OD,barrel or axle OD of about 3 feet, and a width of about 6 feet) holdingabout 10,000 feet of the conveyance structure 2717 of Example 11. Thespool 2715 has a motor drive assembly 2716 that rotates the spool. Thespool has a holding tank 2718 for fluids that may be used with a lasertool or otherwise pumped through the conveyance structure and has avalve assembly for receiving high pressure gas or liquids for flowingthrough the conveyance structure.

The laser 2702 is optically associated with the conveyance structure2717 on the spool 2715 by way of an optical fiber and optical slip ring(not shown in the figures). The fluid tank 2718 and the valve assembly2719 are in fluid communication with the conveyance structure 2717 onthe spool 2715 by way of a rotary slip ring (not shown).

The laser cabin 2710 and handling apparatus cabin 2703 have access doorsor panels (not shown in the figures) for access to the components andequipment, to for example permit repair, replacement and servicing. Atthe back of the handling apparatus cabin 2703 there are door(s) (notshown in the figure) that open during deployment for the conveyancestructure to be taken off the spool. The MLCT 2700 has a generator 2721electrically to provide electrical power to the system.

Turning to FIG. 27D there is shown an embodiment of a deployment of theMLCT 2700. The MLCT 2700 is positioned near a wellhead 2750 having aChristmas tree 2751, a BOP 2752 and a lubricator 2705. The conveyancestructure 2717 travels through winder 2729 (.e.g., line guide,levelwind) to a first sheave 2753, to a second sheave 2754, which has aweight sensor 2755 associated with it. Sheaves 2753, 2754 make up anoptical block. The weight sensor 2755 may be associated with sheave 2753or the composite structure 2717. The conveyance structure 2717 entersinto the top of the lubricator and is advanced through the BOP 2752,tree 2751 and wellhead 2750 into the borehole (not shown) below thesurface of the earth 2756. The sheaves 2753, 2754 have a diameter ofabout 3 feet. In this deployment path for the conveyance structure theconveyance structure passes through several radii of curvature, e.g.,the spool and the first and second sheaves. These radii are all equal toor large than the minimum bend radius of the high power optical fiber inthe conveyance structure. Thus, the conveyance structure deployment pathwould not exceed (i.e., have a bend that is tighter than the minimumradius of curvature) the minimum bend radius of the fiber.

Example 15

An embodiment of a high power mobile laser system is shown in FIG. 28.There is provided a mobile high power laser system 2800 having a lasercabin 2801 and an operator booth 2812. The layout and components of thelaser cabin 2801 and the operator booth 2812 are similar to those inExample 14. The system 2800 has a crane 2857 and a lubricator 2805. Thesystem 2800 has a bay 2803 for receiving a handling apparatus having aconveyance structure.

Example 16

The mobile system of Example 15 in which the handling apparatus of theembodiment of FIG. 11 having 10,000 feet of the conveyance structure ofExample 17. The conveyance structure is optically associated to thelaser without the need for an optical slip ring, and the passages of theconveyance structure are in fluid association with a source of fluidwithout the need for a rotating slip ring.

Example 17

The mobile system of Example 15 in which the handling apparatus of theembodiment of FIG. 9 having 11,000 feet of the conveyance structure ofExample 9. The conveyance structure is optically associated to the laserwithout the need for an optical slip ring, and the passages of theconveyance structure are in fluid association with a source of fluidwithout the need for a rotating slip ring.

Example 18

The mobile system of Example 15 in which the bay has been replaced by ahandling apparatus cabin having a spool having 15,000 feet of aconveyance structure and a reverse wrap conveying structure of theembodiment shown in FIG. 12. In this system the conveyance structurewould first be deployed (unwound from the spool) to the general depthwithin a well where the desired laser activity is to take place. Oncedeployed the proximal end of the conveyance structure (i.e., the endstill on, associated with, or near the axle of the spool) would beoptically associated with reverse wrap structure, which in turn isoptically associated with the laser. In this manner the spool could befurther unwound and wound, permitting a laser tool on the distal end ofthe conveyance structure to be moved upon and down within the well. Thereverse wrap structure would prevent any twisting of the conveyancestructure as the spool is wound and unwound to move the laser toolwithin the well bore.

Example 19

An embodiment of a mobile conveyance structure handling apparatus isshown in FIG. 29. A trailer 2901 has a spool 2902, having a barrel OD2903 of about 8 feet and an OD 2904 of about 10 feet. The spool 2902 hasan optical slip ring 2905 and a rotary slip ring 2906. The spool 2902has at least about 4,000 ft of the conveyance structure 2907 of Example11. The spool has a drive mechanism, which is not shown in the figure.During deployment, the conveyance structure 2907 unwound and placed overoptical block 2710, which is a sheave having an OD of about 6 feet.

In use a mobile laser system would positioned near the trailer 2901 andthe laser would be optically associated with the conveyance structure byway of the optical slip ring.

Example 20

An embodiment of a mobile laser system is shown in FIG. 30. A trailer3001 has a spool 3002 having a drum OD of about 10 feet and an OD ofabout 12 ft and having about 5,000 feet of conveyance structure 3003(coiled tubing having a protected optical fiber within). The trailer3001 has a large diameter coil tubing injector 3004, having an OD ofabout 8 feet.

In use a mobile laser system would positioned near the trailer 3001 andthe laser would be optically associated with the conveyance structure byway of the optical slip ring.

Example 21

An embodiment of a mobile laser system deployed at a drill site is shownin FIG. 31. A mobile laser system 3100 for performing laser activitiessuch as drilling, workover and completion and flow control, in aborehole 3101 in the earth 3102. FIG. 31 provides a cut away perspectiveview showing the surface of the earth 3130 and a cut away of the earthbelow the surface 3102. In general and by way of example, there isprovided a source of electrical power 3103, which provides electricalpower by cables 3104 and 3105 to a mobile laser 3106 and a chiller 3107for the laser 3106. The laser provides a laser beam, i.e., laser energy,that can be conveyed by a laser beam transmission means 3108 to a spoolof coiled tubing 3109. A source of fluid 3110 is provided. The fluid,e.g., high pressure gas, including air or nitrogen, is conveyed by fluidconveyance means 3111 to the spool of coiled tubing 3109.

The spool of coiled tubing 3109 is rotated to advance and retract thecoiled tubing 3112. Thus, the laser beam transmission means 3108 and thefluid conveyance means 3111 are attached to the spool of coiled tubing3109 by means of rotating coupling means 3113. The coiled tubing 3112contains a high power optical fiber in a protective tube fortransmitting high power laser energy to the laser tool 3114. The coiledtubing 3112 also contains a means to convey the fluid along the entirelength of the coiled tubing 3112 to the laser tool 3114.

Additionally, there is provided a support structure 3115, which holds aninjector 3116, to facilitate movement of the coiled tubing 3112 in theborehole 3101. Further other support structures may be employed forexample such structures could be derrick, crane, mast, tripod, or othersimilar type of structure or hybrid and combinations of these. In someapplications, as the borehole is advance to greater depths from thesurface 1030, the use of a diverter 3117, a blow out preventer (BOP)3118, and a fluid and/or cutting handling system 3119 may becomenecessary. The coiled tubing 3112 is passed from the injector 3116through the diverter 3117, the BOP 3118, a wellhead 3120 and into theborehole 3101. The fluid is conveyed to the laser tool 3114 in theborehole 3101. At that point the fluid exits the laser cutting tool 3114in association with the laser beam 3124. The wellhead 3120 is attachedto casing. For the purposes of simplification the structural componentsof a borehole such as casing, hangers, and cement are not shown. It isunderstood that these components may be used and will vary based uponthe depth, type, and geology of the borehole, as well as, other factors.

Example 22

An embodiment of a laser trailer and mobile optics lab is provided inFIGS. 32A to 32C. A laser trailer 3210 is connected by electric powerline 3212 to a generator trailer 3210 (which has a 175 kW dieselgenerator). The laser trailer 3210 has a high power laser 3203, achiller 3202. The laser has a high power optical fiber 3213 that isoptically associated with the laser and exits the trailer, or end in aconnector on the wall of the trail, such that another high power fibermay be optically associated to transmit the high power laser beam to anintended location or equipment, for example the system of Example 19.The laser trailer 3210 may have storage areas 3204, 3208, a work area3205, for example a desk or work bench, a control panel 3206 having dataand control lines 3211, flow bench 3207 and a vibrationally isolatedflow bench 3208. The trailer 3210 may also have HVAC unit 3209.

Example 23

An embodiment of a conveyance structure is provided in FIG. 33. Theconveyance structure 3301 has a support structure 3304 that forms a flowpassage 3305. Along the exterior surface of the support structure thereare located openings 3302, which form channels along the length of theouter surface of the conveyance structure. The openings 3302 have acurved inner surface 3303. The arc of the curved inner surface maypreferably be greater than 180 degrees, and more preferably be around270 degrees, thereby forming lips or fingers 3306 a, 3306 b. In this wayoptical fibers, lines and other small pipe and cables may be placed orfitted into these channels as the conveyance structure is being advancedinto a borehole and held in place by the fingers 3306 a and 3306 b. Asthe conveyance structure 3301 is removed from the borehole the opticalfibers, lines, etc. may be stripped or pulled from the channels.

Example 24

An embodiment of a conveyance structure is provided in FIG. 34. Theconveyance structure 3401 has outer channels along the lines of example23 which are formed by openings 3402 in its outer wall. The openingshave a finger 3403 having an enlarged inner cavity 3404. In thisembodiment the optical fibers, lines, small pipes etc. that are placedin the channels may be done so by forcing them in, or by slightlyturning the conveyance structure to move the optical fiber etc. into theinner cavity 3404 where it will be held. The optical fibers etc. may beremoved from the channel in the opposite manner from which they wereinserted.

The tools that are useful with high power laser systems many generallybe laser cutters, laser bottom hole assemblies, laser cleaners, lasermonitors, laser welders and laser delivery assemblies that may have beenadapted for a special use or uses. Configurations of optical elementsfor culminating and focusing the laser beam can be employed with thesetools to provide the desired beam properties for a particularapplication or tool configuration. A further consideration, however, isthe management of the optical affects of fluids or debris that may belocated within the beam path between laser tool and the work surface.

In addition to directly affecting, e.g., cutting, cleaning, welding,etc., a work piece or site, e.g., a tubular, borehole, etc., the systemsand conveyance structures can be used to transmit high power laserenergy to a remote tool or location for conversion of this energy intoelectrical energy, for use in operating motors, sensors, cameras, orother devices associated with the tool. In this manner, for example andby way of illustration, a single optical fiber, or one or more fibers,preferably shielded, have the ability to provide all of the energyneeded to operate the remote tool, both for activities to affect thework surface, e.g., cutting drilling etc. and for other activities,e.g., cameras, motors, etc. The optical fibers of the present inventionare substantially lighter and smaller diameter than conventionelectrical power transmission cables; which provides a potential weightand size advantage to such high power laser tools and assemblies overconventional non-laser technologies.

Photo voltaic (PV) devices or mechanical devices may be used to convertthe laser energy into electrical energy. Thus, as energy is transmitteddown the high power optical fiber in the form high power laser energy,i.e., high power light having a very narrow wavelength distribution itcan be converted to electrical, and/or mechanical energy. Aphoto-electric conversion device is used for this purpose and is locatedwithin, or associated with a tool or assembly. These photo-electricconversion devices can be any such device(s) that are known to the art,or may be later developed by the art, for the conversion of lightenergy, and in particular laser light energy, into electrical,mechanical and/or electro-mechanical energy. Thus, for examplelaser-driven magnetohydrodynamic (laser MHD) devices may be used,theromphotovolatic devices may be used, thermoelectric devices may beused, photovoltaic devices may be used, a micro array antenna assemblythat employs the direct coupling of photons to a micro array antenna(the term micro array antenna is used in the broadest sense possible andwould include for example nano-wires, semi conducting nano-wires,micro-antennas, photonic crystals, and dendritic patterned arrays) tocreate oscillatory motion to then drive a current may be used, astirling engine with the laser energy providing the heat source could beused, a steam engine or a turbine engine with the laser energy providingthe heat source could be used (see, e.g., U.S. Pat. No. 6,837,759, whichuses a chemical reaction as a heat source turbine engine in an ROV, theentire disclosure of which is incorporated herein by reference). Furtherexamples of and teachings regarding such power conversion devices aredisclosed in U.S. Patent Application Ser. No. 61/446,312, the entiredisclosure of which is incorporated herein by reference.

The present systems and conveyance structures provide the ability tohave laser energy of sufficient power and characteristics to betransported over great lengths and delivered to remote and difficult toaccess locations, such as found in the oil, natural gas and geothermalexploration and production. Thus, the present systems and conveyancestructures may be used for drilling and workover and completionsactivities in the oil, natural gas and geothermal areas. These systemsand structures may find use in decommissioning, plugging and abandonmentactivities in the oil, gas and geothermal industry, and also foroff-shore structures, in the nuclear industry, in the chemical industryand in other industries. An example of another application for thepresent systems and conveyance structures would be in field of “flowassurance,” (a broad term that has been recently used in the oil andnatural gas industries to cover the assurance that hydrocarbons can bebrought out of the earth and delivered to a customer, or end user).Moreover, the present systems and conveyance structures would have usesand applications beyond oil, gas, geothermal and flow assurance, andwould be applicable to the, cleaning, resurfacing, removal and clearingaway of unwanted materials in any location that is far removed from alaser source, or difficult to access by conventional technology as wellas assembling and monitoring structures in such locations. They may alsobe used for the cleaning, resurfacing, removal, and clearing away ofunwanted materials, e.g., build-ups, deposits, corrosion, or substances,in, on, or around structures, e.g. the work piece, or work surface area.Such unwanted materials would include by way of example rust, corrosion,corrosion by products, degraded or old paint, degraded or old coatings,paint, coatings, waxes, hydrates, microbes, residual materials,biofilms, tars, sludges, and slimes.

High power optical fibers that may be used with, in conjunction with, oras a high power conveyance structures would include the followingExamples 25 to 34.

Example 25

An embodiment of an optical fiber has a stainless steel metal tube, thetube having an outside diameter of about ⅛″ (“inch”). The optical fiberhas a core diameter of about 1000 μm, (microns), a cladding thickness ofabout 50 μm, (the thickness of a layer or coating is measured from theinternal diameter or inner surface of the layer or coating to the outerdiameter or outer surface of the layer or coating) and an acrylatecoating thickness of about 100 μm.

Example 26

An embodiment of an optical fiber has a core diameter of about 600 μm,(microns), a cladding thickness of about 30 μm, and an acrylate coatingthickness of about 75 μm. The optical fiber cable may be an opticalfiber with any added outer protective layers.

Example 27

An embodiment of an optical fiber has a core of about 1000 μm,(microns), a cladding having a thickness of about 50 μm, and an acrylatecoating having a thickness of about 100 μm.

Example 28

An embodiment of a multi-clad fiber has: a core 1303, having a diameterof about 600 μm and an NA of about 0.2; a first cladding 1305 (which isadjacent the core) having an outer diameter of about 645 μm and an NA of0.24; a second cladding 1307 (which is adjacent the first cladding) andhaving an outer diameter of about 660 μm and an NA of 0.35; a layer ofsilicone (which is adjacent to the second cladding) and having an outerdiameter of about 685 μm; and, an layer of acrylate (which is adjacentthe silicone layer) and having an outer diameter of about 810 μm.

Example 29

Double-clad and Multi-clad fiber optics may be utilized and provebeneficial to particular applications and in particular when the distalend is optically associated with a connector, such as the connectorsprovided in U.S. Patent Application Ser. No. 61/493,174, the entiredisclosure of which is incorporated herein by reference. A double-cladfiber may reduce or eliminate the need for mode stripping or may be usedto augment the ability to manage back reflections in association with aconnector. Additionally, a fiber that can propagate cladding modes hasthe advantage of affording flexibility around the location of modestripping should it be preferred. The thickness of the outer clad may bechosen so as to minimize the probability of back reflections couplinginto it. In these embodiments, the NA of the fiber core may, forexample, be between about 0.06 and 0.48, with index of refractionbetween about 1.4 and 2, for wavelengths between about 200 nm and 15 μm.The NA of the first clad, if present, may be between about 0 (and morepreferably 0.01) and 0.48, with index of refraction between about 1.4and 2, for wavelengths between about 200 nm and 15 μm. The NA of thesecond clad, if present, may be between about 0 (and more preferably0.01) and 0.48, with index of refraction between about 1.4 and 2, forwavelengths between about 200 nm and 15 μm. The NA of further clads, ifpresent, may be between about 0 (and more preferably 0.01) and 0.48,with index of refraction between about 1.4 and 2, for wavelengthsbetween about 200 nm and 15 μm. The index of refraction of the buffer,if present, may be between about 1.4 and 2, for wavelengths betweenabout 200 nm and 15 μm. Combinations of single, double, and multi-cladfibers may also be used.

Example 30

An embodiment of an optical fiber has a core, first clad, second clad,silicone buffer, and Teflon-style coating. The core having an NA ofabout 0.2, and an index of about 1.450 at the wavelength of 1070 nm. Thefirst clad having an NA of about 0.23, and an index of about 1.436 atthe wavelength of 1070 nm. The second clad having an NA of about 0.35,and an index of about 1.417 at the wavelength of 1070 nm. The siliconehaving an index of about 1.373 at the wavelength of 1070 nm.

Example 31

An embodiment of an optical fiber has a core, first clad, andacrylate-style coating. The core having an NA of about 0.2, and an indexof about 1.45 at the wavelength of 1070 nm. The first clad having anindex of about 1.436 at the wavelength of 1070 nm.

Example 32

An embodiment of an optical fiber has a core, first clad, second clad,and Polyimide-style coating. The core having an NA of about 0.1, and anindex of about 1.45 at the wavelength of 1070 nm. The first clad havingan NA of about 0.12, and an index of about 1.447 at the wavelength of1070 nm. The second clad having an NA of about 0.2, and an index ofabout 1.442 at the wavelength of 1070 nm. The polyimide having an indexof about 1.428 at the wavelength of 1070 nm.

Example 33

An embodiment of an optical has a core, first clad, and acrylate-stylecoating. The core having an NA of about 0.2, and an index of about 1.5at the wavelength of 2000 nm. The first clad having an index of about1.487 at the wavelength of 2000 nm.

Example 34

An embodiment of an optical fiber has a core, first clad, second clad,silicone buffer, and Teflon-style coating. The core having an NA ofabout 0.2, and an index of about 1.450 at the wavelength of 1070 nm. Thefirst clad having an NA of about 0, and an index of about 1.436 at thewavelength of 1070 nm. The second clad having an NA of about 0.35, andan index of about 1.450 at the wavelength of 1070 nm. The siliconehaving an index of about 1.407 at the wavelength of 1070 nm.

In addition to step index fibers, for example of the types provided inExamples 30 to 34, other step index configurations may be utilized.Additionally, fibers of other configurations, shapes and types may beutilized, such as for example fibers with air clads, polymer clads, orgraded index fibers.

Additionally, the buffer or jacket coating may preferably be tefzel,teflon, or another fluoropolymer or similar material which hassignificant transmission at the desired wavelength, and substantialtemperature capability for the selected application.

The various embodiments of conveyance structures set forth in thisspecification may be used with the various high power laser systems setforth in this specification. The various embodiments of conveyancestructures set forth in this specification may be used with other highpower laser systems that may be developed in the future, or withexisting non-high power laser systems, which may be modified in-partbased on the teachings of this specification, to create a laser system.The various embodiments of high power laser systems may also be usedwith other conveyance structures that may be developed in the future, orwith existing structures, which may be modified in-part based on theteachings of this specification to provide for the transmission of highpower laser energy. Further the various handling apparatus, opticalfibers, and other equipment set forth in this specification may be usedwith the various conveyance structures, high power laser systems, andcombinations and variations of these, as well as, future structures andsystems, and modifications to existing structures and systems basedin-part upon the teachings of this specification. Thus, for example, thestructures, fibers, equipment, apparatus, and systems provided in thevarious Figures and Examples of this specification may be used with eachother and the scope of protection afforded the present inventions shouldnot be limited to a particular embodiment, configuration or arrangementthat is set forth in a particular embodiment in a particular Figure.

Many other uses for the present inventions may be developed or releasedand thus the scope of the present inventions is not limited to theforegoing examples of uses and applications. The present inventions maybe embodied in other forms than those specifically disclosed hereinwithout departing from their spirit or essential characteristics. Thedescribed embodiments are to be considered in all respects only asillustrative and not restrictive.

1: A mobile high power laser system comprising: a laser cabin, the lasercabin housing a high power laser system having the capability togenerate a laser beam having at least about 10 kW of power and awavelength in the range of about 800 nm to about 2100 nm; a conveyancestructure having a length of at least about 3,000 feet; the conveyancestructure comprising: a high power optical fiber having a core diameterof at least about 500 )lm and a length of at least about 3,000 ft, afirst support structure having a length of at least about 3,000 feet, asecond support structure having a length of at least about 3,000 feet, adata or control line having a length of at least about 3,000 feet, and apassage defined by the first or second support structure, the passagehaving a length of at least about 3,000 feet; and a means for handlingthe conveyance structure. 2: The mobile high power laser system of claim1, wherein the means for handling comprises an injector. 3: The mobilehigh power laser system of claim 1, wherein the means for handlingcomprises a spool and an optical slip ring. 4: The mobile high powerlaser system of claim 2, comprising a second passage and wherein theline provides electric power. 5: The mobile high power laser system ofclaim 1, comprising an optical block. 6: A mobile high power lasersystem comprising: a laser cabin, the laser cabin housing a high powerlaser having the capability to generate a laser beam having at leastabout 10 kW of power; a conveyance structure having a length of at leastabout 4,000 feet; the conveyance structure comprising: a high poweroptical fiber having a core diameter of at least about 300 )lm and alength of at least about 4,000 feet, an outer support structure having alength of at least about 4,000 feet, an inner support structure having alength of at least about 4,000 feet, a data or control line having alength of at least about 4,000 feet, and a passage defined by the inneror the outer support structure, the passage having a length of at leastabout 4,000 feet; and a means for handling the conveyance structure. 7:The mobile laser system of claim 6, wherein the lengths of the opticalfiber, the outer support structure, the inner support structure, theline, and the passage are at least about 5,000 feet. 8: The mobile lasersystem of claim 6, wherein the lengths of the optical fiber, the outersupport structure, the inner support structure, the line, and thepassage are at least about 10,000 feet. 9: The mobile high power lasersystem of claim 6, wherein the means for handling comprises an injector.10: The mobile high power laser system of claim 6, wherein the means forhandling comprises a spool and an optical slip ring. 11: The mobile highpower laser system of claim 6, comprising a second passage and whereinthe line provides electric power. 12: The mobile high power laser systemof claim 6, comprising an optical block. 13: A mobile high power lasersystem comprising: a. a base; b. a means for providing a high powerlaser beam having at least 5 kW of power; c. a means for containing ahandling apparatus; d. an operator station; and, e. a means forproviding electrical power. 14: The mobile high power system of claim13, wherein the base comprises a truck chassis; wherein the means forproviding the high power laser beam comprises a mobile laser room andwherein the mobile laser room is mounted to the truck chassis; whereinthe means for containing the handling apparatus comprises a handlingapparatus cabin or a handling apparatus bay and comprises a handlingapparatus comprising at least about 4,000 feet of a high powerconveyance structure; and wherein the operator station is controllablyassociated with the mobile laser room and the handling apparatus. 15:The mobile high power system of claim 13, wherein the base comprises atrailer; wherein the means for providing the high power laser beamcomprises a mobile laser room; wherein the means for containing thehandling apparatus comprises a handling apparatus cabin or a handlingapparatus bay, and comprises a handling apparatus comprising at leastabout 4,000 feet of a high power conveyance structure and is mounted tothe trailer, and wherein the operator booth is controllably associatedwith the mobile laser room and the handling apparatus. 16: A mobile highpower laser system comprising: a. a laser housing; b. a handlingapparatus; c. a high power laser capable of generating at least a 10 kWlaser beam within the laser housing; d. a conveyance structurecomprising a high power optical fiber, a passage, a line and a supportstructure, wherein the high power optical fiber having a core diameterof at least about 300 )lm and a minimum bend radius; and, e. an opticalblock having a radius of curvature, wherein the optical block radius ofcurvature is greater than, equal to, or within 5% less than the radiusof curvature of the high power optical fiber. 17: The mobile high powerlaser system of claim 16, comprising at least 5,000 feet of conveyancestructure and wherein the core diameter is at least about 450 μm. 18:The mobile high power laser system of claim 17, wherein the high powerlaser is capable of generating a laser beam of at least 20 kW. 19: Themobile high power laser system of claim 16, wherein the laser housingand the handling apparatus are associated with a platform. 20: Themobile high power laser system of claim 16, wherein the laser housing isassociated with a first mobile base and the handling apparatus isassociated with a second mobile base. 21: A mobile high power lasersystem comprising: a. a base; b. the base having a laser housing, anoperator housing and a handling apparatus; c. a chiller, a storage tank,and a laser capable of generating at least a 10 kW laser beam beingassociated with the laser housing; d. a conveyance structure comprisinga high power optical fiber, a passage, a line and a support structure,wherein the high power optical fiber has a minimum bend radius; and, e.an optical block having a radius of curvature, wherein the optical blockradius of curvature is greater than or substantially equal to the radiusof curvature of the high power optical fiber. 22: The mobile high powerlaser system of claim 21, wherein the conveyance structure is at least5,000 feet. 23: The mobile high power laser system of claim 22, whereinthe support structure of the conveyance structure defines an outersurface for the conveyance structure. 24: The mobile high power lasersystem of claim 23, wherein the high power optical fiber is at leastpractically contained within the support structure. 25: The mobile highpower laser system of claim 24, wherein the high power optical fiberforms at least a portion of the outer surface for the conveyancestructure. 26: The mobile high power laser system of claim 22, whereinthe high power optical fiber and the line are inside of the supportstructure. 27: The mobile high power laser system of claim 23, whereinthe wavelength of the laser beam is from about 800 nm to about 2100 nm.28: The mobile high power laser system of claim 23, wherein thewavelength of the laser beam is from about 1060 nm to about 1800 nm. 29:The mobile high power laser system of claim 23, wherein the wavelengthof the laser beam is from about 1800 nm to about 2100 nm. 30: The mobilehigh power laser system of claim 21, comprising a second high poweroptical fiber and a passage. 31: The mobile high power laser system ofclaim 21, comprising a plurality of lines, a plurality of high poweroptical fibers, and a plurality of support structures. 32: The mobilehigh power laser system of claim 21, wherein the optical block isassociated with the base. 33: The mobile high power laser system ofclaim 21, wherein the base is a trailer. 34: The mobile high power lasersystem of claim 21, wherein the base is a truck chassis. 35: The mobilehigh power laser system of claim 21, wherein the base is a skid. 36: Themobile high power laser system of claim 21, wherein a shipping containerdefines at least the laser housing. 37: The mobile high power lasersystem of claim 21, wherein the chiller is located within the laserhousing and comprising: air intake and exhaust means are associated withthe chiller and provided in the laser housing; and at least one storagetank comprises a heating element. 38-40. (canceled) 41: The mobile highpower laser system of claim 21, wherein the high power optical fiberforms at least a portion of the outer surface for the conveyancestructure and wherein the conveyance structure is at least 3,000 feetand the optical fiber comprises a core having a core diameter of atleast about 500 )lm. 42-45. (canceled) 46: A high power laser systemcomprising: a. a mobile platform; b. a laser housing associated with themobile platform; c. a chiller, and a laser capable of generating atleast a 10 kW laser beam; d. at least 1,000 feet of a conveyancestructure comprising a high power optical fiber and a protectivestructure, wherein the high power optical fiber has a core having adiameter of at least about 300 )lm and a minimum bend radius; and, e. anoptical block having a radius of curvature, wherein the optical blockradius of curvature is greater than about 3% less than the radius ofcurvature of the high power optical fiber. 47: The high power lasersystem of claim 46, wherein the laser is capable of generating at leasta 20 kW laser beam. 48: The high power laser system of claim 46, whereinthe laser is capable of generating at least a 30 kW laser beam. 49: Thehigh power laser system of claim 46, wherein the laser is capable ofgenerating at least a 50 kW laser beam. 50: The high power laser systemof claim 46, wherein the laser comprises a first laser capable ofproviding at least a 5 kW laser beam and a second laser capable ofproviding at least a 5 kW laser. 51: The high power laser system ofclaim 46, wherein the laser comprises a plurality of lasers each capableof generating a laser beam having a power, wherein the combined power ofthe plurality of laser beams is at least about 10 kW. 52: The high powerlaser system of claim 47, wherein the laser comprises a first lasercapable of providing at least a 10 kW laser beam and a second lasercapable of providing at least a 10 kW laser. 53: The high power lasersystem of claim 49, wherein the laser comprises a first laser capable ofproviding at least a 20 kW laser beam, a second laser capable ofproviding at least a 20 kW laser beam and a thirds laser capable ofproviding at least a 20 kW laser beam. 54: The high power laser systemof claim 47, wherein the laser comprises a plurality of lasers eachcapable of generating a laser beam having a power, wherein the combinedpower of the plurality of laser beams is at least about 20 kW. 55: Thehigh power laser system of claim 49, wherein the laser comprises aplurality of lasers each capable of generating a laser beam having apower, wherein the combined power of the plurality of laser beams is atleast about 50 kW. 56-58. (canceled) 59: The mobile high power lasersystem of claim 46, wherein the high power optical fiber forms at leasta portion of the outer surface for the conveyance structure and whereinthe conveyance structure is at least 3,000 feet and the optical fibercomprises a core having a core diameter of at least about 500 )lm.60-61. (canceled) 62: The mobile high power laser system of claim 46,wherein the conveyance structure comprises a passage. 63: The mobilehigh power laser system of claim 46, wherein the conveyance structurecomprises a plurality of lines, a plurality of high power opticalfibers, and a plurality of support structures.
 64. (canceled) 65: A highpower laser system comprising: a. a mobile platform; b. a laser housingassociated with the mobile platform; c. a laser system capable ofgenerating at least a 10 kW laser beam; d. a conveyance structurecomprising a high power optical fiber and a protective structure,wherein the high power optical fiber has a minimum bend radius; and, e.the conveyance structure associated with a handling apparatus forholding and deploying the conveyance structure, wherein the handlingapparatus is configured to maintain the radius of curvature for theoptical fiber at a radius that is greater than, equal to, or within 5%less than the minimum bend radius. 66: The high power laser system ofclaim 65, comprising a chiller. 67: The high power laser system of claim646, wherein at least a portion of the chiller is exterior to the laserhousing. 68: The high power laser system of claim 65, comprising anoptical block. 69: The high power laser system of claim 65, wherein thehandling apparatus is configured to maintain the radius of curvature forthe conveyance structure at a radius that is at least 1% greater thanthe minimum bend radius. 70: The high power laser system of claim 65,wherein the handling apparatus is configured to maintain the radius ofcurvature for the conveyance structure at a radius that is at least 2%greater than the minimum bend radius. 71: The high power laser system ofclaim 65, wherein the handling apparatus is configured to maintain theradius of curvature for the conveyance structure at a radius that is atleast 5% greater than the minimum bend radius. 72: The high power lasersystem of claim 65, wherein the handling apparatus is configured tomaintain the radius of curvature for the conveyance structure at aradius that is at least 1% greater than the minimum bend radius. 73: Thehigh power laser system of claim 65, wherein the handling apparatus isassociated with a second mobile platform. 74: The high power lasersystem of claim 65, wherein the handling apparatus is associated withthe mobile platform. 75-77. (canceled) 78: The mobile high power lasersystem of claim 65, wherein the high power optical fiber forms at leasta portion of the outer surface for the conveyance structure and whereinthe conveyance structure is at least 3,000 feet and the optical fibercomprises a core having a core diameter of at least about 500 )lm. 79:The mobile high power laser system of claim 65, wherein the conveyancestructure comprises a line structure. 80-81. (canceled) 82: The mobilehigh power laser system of claim 65, wherein the conveyance structurecomprises a plurality of lines, a plurality of high power opticalfibers, and a plurality of support structures. 83-95. (canceled) 96: Ahigh power laser system deployed at a well site, the system comprising:a. a high power laser system capable of generating at least a 10 kWlaser beam; b. a chiller; c. a conveyance structure deployment device;d. an optical block; e. a conveyance structure having a distal end and aproximal end and comprising a high power optical fiber having a minimalbend radius; f. a lubricator; g. wherein the proximal end of theconveyance structure is optically associated with the high power laserand associated with the deployment device; wherein the conveyancestructure is at least practically held by the deployment device andextends from the deployment device to the optical block and extends fromthe optical block to and into the lubricator, thereby defining aconveyance structure deployment path; wherein the lubricator is incommunication with a well at the well site; and, h. the conveyancestructure deployment path does not exceed the minimum bend radius forthe optical fiber. 97: The high power laser system of claim 96,comprising a generator. 98: The high power laser system of claim 96,wherein the laser system is mounted on a mobile platform. 99: The highpower laser system of claim 98, wherein the mobile platform is a truck.100: The high power laser system of claim 98, wherein the mobileplatform is a trailer. 101: The high power laser system of claim 96,wherein the laser comprises a first laser capable of providing at leasta 10 kW laser beam and a second laser capable of providing at least a 10kW laser. 102: The mobile high power laser system of claim 96, whereinthe high power optical fiber forms at least a portion of the outersurface for the conveyance structure and wherein the conveyancestructure is at least 3,000 feet and the optical fiber comprises a corehaving a core diameter of at least about 300 μm. 103: The mobile highpower laser system of claim 96, wherein the conveyance structurecomprises a data or control line. 104-105. (canceled) 106: The mobilehigh power laser system of claim 96, wherein the conveyance structurecomprises a passage. 107: The mobile high power laser system of claim97, wherein the conveyance structure comprises a passage. 108: Themobile high power laser system of claim 96, wherein the conveyancestructure comprises a plurality of lines, a plurality of high poweroptical fibers, and a plurality of support structures. 109: A high powerlaser system deployed at a well site, the system comprising: a. a meansfor generating a high power laser beam having at least a 10 kW of power;b. a means for deploying a conveyance structure; c. a conveyancestructure having a distal end and a proximal end and comprising a highpower optical fiber having a minimal bend radius and having a corediameter of at least about 300 μm; d. a means for entering a well, e.wherein the proximal end of the conveyance structure is opticallyassociated with the high power laser; wherein the conveyance structureis at least practically held by the means for deploying and extends toand into the means for entering a well, thereby defining a conveyancestructure deployment path; wherein the means for entering the well is incommunication with a well at the well site; and, f. the conveyancestructure deployment path does not exceed the minimum bend radius forthe optical fiber. 110: A laser work over and completion unitcomprising: a. a base; b. a handling apparatus associated with the base;c. a means for receiving a laser beam having at least a 5 kW laser beambeing associated with the handling apparatus; d. a conveyance structurecomprising a means for transmitting a laser beam having at least 5 kW ofpower over at least 3,000 without substantial power loss: a passage, aline and a support structure, wherein the means for transmitting has aminimum bend radius; and, e. an optical block having a radius ofcurvature, wherein the optical block radius of curvature is greaterthan, equal to, or within 5% less than the radius of curvature of themeans for transmitting. 111: The unit of claim 110, wherein theconveyance structure is at least 5,000 feet long and comprising a meansfor transmitting a laser beam having at least 5 kW of power over atleast 5,000 feet. 112: The unit of claim 110, wherein the conveyancestructure is at least 10,000 feet long and comprising a means fortransmitting a laser beam having at least 5 kW of power over at least10,000 feet. 113: The unit of claim 110, wherein the support structureof the conveyance structure defines an outer surface for the conveyancestructure. 114: The unit of claim 110, comprising a high power lasercapable of generating a laser beam having at least about 5 kW of power.115: The unit of claim 110, wherein the means for transmitting is atleast practically contained within the support structure. 116: The unitof claim 110, wherein the means for transmitting forms at least aportion of an outer surface for the conveyance structure. 117: The unitof claim 110, wherein the conveyance structure comprises a plurality oflines, a plurality of high power optical fibers, and a plurality ofsupport structures. 118: A laser workover and completion system deployedat a well site, the system comprising: a. a conveyance structuredeployment device; b. an optical block; c. a conveyance structure havinga distal end and a proximal end and comprising a high power opticalfiber having a proximal end and a distal end, and having a minimal bendradius, the proximal end of the high power optical fiber being capableof receiving a high power laser beam and the high power optical fiberbeing capable of transmitting a high power laser beam withoutsubstantial power loss; d. a lubricator; e. wherein the proximal end ofthe conveyance structure is associated with the deployment device;wherein the conveyance structure is at least practically held by thedeployment device and extends from the deployment device to the opticalblock and extends from the optical block to and into the lubricator,thereby defining a conveyance structure deployment path; wherein thelubricator is in communication with a well at the well site; and, f. theconveyance structure deployment path does not exceed the minimum bendradius for the optical fiber. 119: A laser workover and completionsystem deployed at a well site, the system comprising: a. a conveyancestructure deployment device; b. an optical block; c. a conveyancestructure having a distal end and a proximal end and comprising a highpower optical fiber having a minimal bend radius; d. a means forentering a well; e. wherein the proximal end of the conveyance structureis optically associated with the high power laser and associated withthe deployment device; wherein the conveyance structure is at leastpractically held by the deployment device and extends from thedeployment device to the optical block and extends from the opticalblock to and into the means for entering a well, thereby defining aconveyance structure deployment path; wherein the means for entering thewell is in communication with a well at the well site; and, f. theconveyance structure deployment path does is greater than, equal to, orwithin 5% less than the minimum bend radius for the optical fiber. 120:A high power laser conveyance structure comprising: a. a first layercomprising a plurality of wound armor wires; b. a second layercomprising a plurality of wound armor wires, wherein the second layer ispositioned inside of the first layer; c. the second layer forming acavity; d. the cavity containing a high power optical fiber; e. the highpower optical fiber comprising a core and a cladding; f. the high poweroptical fiber being capable of reducing a non-linear effect when a highpower laser beam is propagated through the optical fiber; and, g. theconveyance structure being at least 2,000 feet long. 121: The high powerlaser conveyance structure of claim 120, wherein the length is at least5,000 feet. 122: A high power laser conveyance structure comprising: a.a first layer comprising a plurality of wound armor wires; b. a secondlayer comprising a plurality of wound armor wires, wherein the secondlayer is positioned inside of the first layer; c. the second layerforming a cavity; d. the cavity containing a plurality of electricalconductors and a high power optical fiber; e. the high power opticalfiber comprising a core, a cladding and a protective layer; f. the highpower optical fiber being capable of reducing a non-linear effect when ahigh power laser beam is propagated through the optical fiber; and, g.the conveyance structure being at least 2,000 feet long. 123: The highpower laser conveyance structure of claim 122, wherein the length is atleast 5,000 feet. 124: A high power laser conveyance structurecomprising: a. a support structure; b. a line associated within thesupport structure; c. a high power optical fiber associated with thesupport structure; d. a passage associated with the support structurefor transporting a fluid; and, e. the high power optical fiber beingcapable of reducing a non-linear effect when a high power laser beam ispropagated through the optical fiber over distances greater than 2,000feet. 125: The conveyance structure of claim 124, wherein the conveyancestructure has an outer surface comprising the support and wherein theline is associated with the outer surface. 126: The conveyance structureof claim 124, wherein the conveyance structure has an outer surfacecomprising the support and wherein the fiber is associated with theouter surface. 127: The conveyance structure of claim 124, wherein thepassage is defined by the support structure. 128: The conveyancestructure of claim 124, comprising a second support structure. 129: Theconveyance structure of claim 124, comprising a second passage. 130: Theconveyance structure of claim 124, wherein the fluid is selected fromthe group consisting of air, gas, nitrogen, and liquid. 131: Theconveyance structure of claim 124, wherein the support structurecomprises a material selected from the group consisting of wire, carbonfiber, composites, polymers, and metal tubing. 132: A high power lasersystem comprising: a. a mobile platform; b. a laser housing associatedwith the mobile platform; c. a laser system capable of generating atleast a 10 kW laser beam; d. a conveyance structure comprising a highpower optical fiber and a protective structure, wherein the high poweroptical fiber has a minimum bend radius; and, e. the conveyancestructure associated with a handling apparatus for holding and deployingthe conveyance structure, wherein the handling apparatus is configuredto maintain the radius of curvature for the optical fiber at a radiusthat is more than about 5% less than the minimum bend radius.